SM 33 PDF

Service
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Workshop Manual
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SpaceFox, Space Cross, Suran, Suran
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Cross, Sportvan 2006 ➤
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Brake systems
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Edition 05.2011
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
45 - Anti-lock Braking System (ABS)
46 - Brakes - Mechanical system
47 - Brakes - Hydraulic system, servo brake
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2015 Volkswagen AG, Wolfsburg D3E802FFE59

SpaceFox, Space Cross, Suran, Suran Cross, Sportvan 2006 ➤
Brake systems - Edition 05.2011
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Brake PR number correspondence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Brake technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
45 - Anti-lock Braking System (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 Information on repair works on the ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Connect the Diagnosis, Measurement and Information System VAS 5051A/52 and select the
functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 General information on the Bosch 5.7 antilock braking system (ABS) . . . . . . . . . . . . . . . . 5
6 Electrical/electronic components and installing locations . . . . . . . . . . . . . . . . . . . . . . . . . . 8
6.1 ABS Bosch 5.7 . . . . . . . . . . . . . . . . . . . . .ag.e.n.A.G.. V. o.lk.s.w.ag. e.n.A.G. d.o. . . . . . . . . . . . . . . . . . . . . 8
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6.2 ABS Bosch 8.0 (ABS/ESP) . . . . . . y. V.o.lk.s . . . . . . . . . . . . . . . . . . . n. o.t g. u. . . . . . . . . . . . . . . . 9
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6.3 ABS Bosch 8.2 . . . . . . . . . . . .or.ise. d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.an.te. . . . . . . . . . . . . 10
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7 Hydraulic unit, servo brake/master au cylinder - Bosch 5.7 (up to model 2011) - Assembly ra
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overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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7.1 Hydraulic unit connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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7.2 Control unit and hydraulic unit - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
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7.3 ABS control unit J104 from the ABS hydraulic unit N55 - Remove and install . . . . . . . . . . 19
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7.4 Brake pressure Sensor 1 G201 - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
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8 Hydraulic unit, servo brake/brake cylinder - Assembly overview (Bosch 8.0 / 8.2) . . . . . . 23
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8.1 Hydraulic unit connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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8.2 ABS control unit J104 on the ABS hydraulic unit N55 - remove and install . . . . . . . . . . . . 25
9 Fault indication via control lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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9.1 Control lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
10 ABS system components on the front and rear axles - remove and install . . . . . . . . . . . . 36
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10.1 ABS system components on the front axle - remove and install . . . . . . . . . . . . . . . . . . . . 36
10.2 Bosch 5.7 front speed sensor cables - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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10.3 Bosch 8.0 / 8.2 front speed sensor cables - remove and install . . . . . . . . . . . . . . . . . . . . . . 40
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10.4 ABS system components on rear axle (vehicles with drum brakes) - remove and install . . 41
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11 ESP system components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

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11.1 Lateral tilting intensity sensor G202 and Lateral acceleration sensor G200 - remove and
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install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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11.2 Steering angle sensor G85 - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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46 - Brakes - Mechanical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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1 Front wheel brake - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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1.1 Front wheel brake (FS ll) - assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.2 Brake pads (FS II) - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.3 Brake caliper (FS II) - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.4 Front wheel brake (FS ll) - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.5 Brake pads (FS III) - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.6 Brake caliper (FS III) - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
1.7 Brake disc with visual check - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2 Rear wheel brake (drum brake) - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.1 Brake drum - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.2 Brake shoes - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3 Parking brake - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.1 Parking brake cable (drum brake) - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Contents i
3.2 Parking brake - adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

4 Brake pedal - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.1 Pedal set - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.2 Brake pedal - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.3 Brake pedal switch F47 - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
47 - Brakes - Hydraulic system, servo brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

1 Front brake caliper (FS II) - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
1.1 Plunger for front brake caliper - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2 Front brake caliper, brake caliper (FS II) - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.1 Front brake caliper plunger - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3 Braking power adjustment - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.1 Brake pressure regulator - adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.2 Brake pressure regulator - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4 Brake system - bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.1 Brake system - Bleed with brake replenishment and bleed equipment . . . . . . . . . . . . . . . . 85
4.2 Brake system - Bleed without brake replenishment and bleed equipment . . . . . . . . . . . . . . 86
4.3 Brake system with ABS/EDS/ASR AG. Volkswagen AGthe
agen - Bleed when doesreservoir is empty . . . . . . . . . . . . . . 86
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5.1 Servo brake vacuum hor pump (diesel vehicles) - remove and install
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5.2 Check valve -sscheck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.c . . . . . . . . . . . . . . . . . . . .
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6 Brake cylinder - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

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6.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
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6.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
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7 Servo brake - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

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7.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . h re 94
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7.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
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ii Contents
00 – Technical data
1 Technical data
1.1 Brake PR number correspondence

Information about which brake is installed in a vehicle is on the
vehicle identification label with its respective PR number.
Example of a vehicle identification label
In this example, the following brake is installed in the vehicle:
♦ -1- Rear wheel brake (-1KM-Drum brake).
♦ -2- Front wheel brake with bracket (-1LR-Disc Brake FS III).
The vehicle ID label is located in the spare wheel housing and in
the Maintenance and Warranty book.
The following table displays gthe APR
G. Vonumber
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PR number Front wheel brake

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1LM / 1LA / 1ZN FS II (13”)

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1LG / 1ZF / 1ZR/1LR FS III (14”)

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PR number Rear wheel brake

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1KM TB 200 X 40 CR 19mm

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1. Technical data 1
1.2 Brake technical data

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Brake disc, mm 22 es, in part or in w
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-2- Brake pad, mm 14,17
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-3- Brake caliper, ∅ 54
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-4- Brake caliper FS III (15”)
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-2- Brake pad, mm 5

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Brake pad, mm 38.8
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-3- Brake drum ∅ 200
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1.2.3 Rear wheel brake (drum brake, with

ABS)
PR number 1KM
Brake cylinder ∅ 20,64
mm
Servo brake ∅ pol 8,544′′
-1- Wheel brake ∅ 17,46
cylinder mm
-2- Brake pad, mm 5
thickness
Brake pad, mm 38,8
width
-3- Brake drum ∅ 200
mm
2 Rep. Gr.00 - Technical data

45 – Anti-lock Braking SystemVol(ABS)

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1 Information on repair works on the au
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♦ With the ignition turned off, disconnect the battery earth strap.
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♦ Prior welding with the electrical welding equipment urposes, in part or in wh
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♦ Observe the effective measures and notes when handing the
brake fluid, ⇒ page 85
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♦ After service requiring opening of the break system, bleed the
brake system with the Brake filling and bleeding equipment -
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VAS 5234- or the Brake pedal compression device -VAG
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♦ During the test drive, ensure at least one brake adjustment is
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performed (a slight pulsing on the brake pedal shall be felt).

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♦ While working on the ABS system, a high level of cleanliness
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♦ Carefully clean the union areas and surrounding surfaces be‐
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♦ The components removed must be placed on a clean surface

and covered over.
♦ If the repairs are not carried out immediately, carefully cover
the open components or place them in the proper location.
(Use the lid from repair set 1H0 698 311 A)
♦ Use cloths that do not fray.
♦ Only remove the replacement parts from their packages im‐
mediately before assembly.
♦ Use only parts in original packaging.
♦ Do not work with compressed air nor move the vehicle with the
system open.
♦ Make sure that no brake fluid comes into contact with the con‐
nectors.
♦ For painting jobs, the command unit may be momentaneously
submitted to a maximum temperature of 95 °C, and for longer
periods (about 2 hours) with max. 85 °C.
1. Information on repair works on the ABS 3

2 Connect the Diagnosis, Measure‐

ment and Information System -VAS
5051A/52- and select the functions
Special tools and workshop equipment required
♦ Diagnosis, Measurement and Information System -VAS
5051A/52-
♦ Diagnostic cable -VAS 5051/1- or Diagnostic cable -VAS
5051/3-
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♦ During a test drive, the measuring and checking equip‐
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♦ During a test drive, only one person should operate this

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– Connect the diagnostic cable connector Diagnostic cable -

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VAS 5051/1- or the Diagnostic cable -VAS 5051/3- to the

diagnostic connection -arrow-.
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– Connect the Diagnosis, Measurement and Information Sys‐

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4 Rep. Gr.45 - Anti-lock Braking System (ABS)

3 General information on the Bosch 5.7

antilock braking system (ABS)
The ABS brake system is arranged diagonally. The braking power
amplification is carried out pneumatically through the vacuum
servo brake.
Failures on the ABS do not influence the brake system and the
servo brake. The conventional braking system remains functional
even without the ABS. Expect an alteration on the brake system
operation. After the ABS control lamp lights up, the rear wheels
may lock in advance!
In case there are any complaints, the hydraulic and control units
shall be replaced together.
Remove and install the control and hydraulic unit ⇒ page 15 .
ABS Location:
1- Hydraulic unit and control unit
2- Servo brake
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3. General information on the Bosch 5.7 antilock braking system (ABS) 5


ABS Bosch 8.0 had the following variants:
♦ ABS
♦ ABS/EDS/ASR/ESP
The ABS brake system is arranged diagonally. The braking power
amplification is carried out pneumatically through the vacuum
servo brake.
Failures on the ABS do not influence the brake system and the
servo brake. The conventional braking system remains functional
even without the ABS. Expect an alteration on the brake system
operation. After the ABS control lamp lights up, the rear wheels
may lock in advance!
Location of the ABS in vehicles with steering wheel on the left
side:
1- Hydraulic unit and control unit
2- Servo brake
The control unit -1- and the hydraulic unit -2- comprise a unit. In
case of damage, replace the control unit and the hydraulic unit as
a set. It is not allowed the separation of the pump -3- from the
hydraulic unit.
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Bosch 8.0 ABS and ABS/ASR: s aut ra
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Hydraulic unit and control unit ⇒ page 23 .
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The ABS brake system (Bosch 8.2) is arranged diagonally. The
braking power amplification is carried out pneumatically through
the vacuum servo brake.
Note
Failures in the ABS do not influence the brake system and the
servo brake. The conventional braking system remains
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even without the ABS. A differenceolkinswthe brake
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ABS location:
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1 - Hydraulic system unit and
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ABS command device
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2 - Servo brake
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Bosch 8.2 (ABS) :

Command device -1- and hydraulic system unit -2- comprise a
unit. In case of damage, replace both the command device and
hydraulic system unit. Do not separate the hydraulic pump -3-
from the hydraulic system unit.
ABS hydraulic unit -N55- and ABS control unit -J104-
⇒ page 10 .
5. General information on the Bosch 8.2 antilock braking system (ABS) 7

6 Electrical/electronic components and

installing locations
6.1 ABS Bosch 5.7

up to the model 2011
1 - ABS hydraulic unit -N55-

The hydraulic unit comprises
the following components:
❑ ABS reflux pump -V39-
❑ Valve block (includes in‐
take and exhaust
valves)
❑ A ABS reflux pump -
V39- and the valve block
must not be separated
❑ Remove and install
⇒ page 15
2 - ABS control unit -J104-
❑ Do not disconnect the
control unit connector
before self-diagnosis
⇒ page 15
3 - Brake pressure Sensor 1 -
G201-
⇒ page 21
4 - Brake light switch -F- and AG. Volkswagen AG d
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❑ Adjust ⇒ page 74sed b ara
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5 - ABS control lightau-K47-
t or
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❑ Installation location: on
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❑ Function: ⇒ page 34
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6 - Brake system control light -

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K118-
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❑ Installation location: on
spec
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❑ Function: ⇒ page 34
7 - Diagnosis connection
rrectne
❑ Installation location: footwell lining on the driver's side

8 - Steering angle sensor -G85-
ss o
❑ Installation location: at the steering column between the steering wheel and the steering column switch
cial p
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9 - Lateral acceleration sensor -G200- and Lateral tilting intensity sensor -G202-
mer
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❑ Installation location: at the left seat transverse bracket on the floor plate
om
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10 - ESP button
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❑ Installation location: if there is any, on the instrument panel

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Rep. Gr.45 - Anti-lock Braking System (ABS) Prote
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11 - Front right wheel rotation sensor -G45- and Left front wheel rotation sensor -G47-
❑ Replace ⇒ page 36
12 - Rear right wheel rotation sensor -G44- and Left rear wheel rotation sensor -G46-
❑ Replace ⇒ page 36
13 - Wheel hub/roller bearing assembly
❑ The ABS sensor ring is assembled to the wheel bearing
❑ The ABS sensor ring is assembled to the wheel bearing
6.2 ABS Bosch 8.0 (ABS/ESP)

up to the model 2011

❑ It can be checked in the
function “Assisted trou‐
bleshooting” with Diag‐
nosis, Measurement
and Information System
-VAS 5051A/52-
❑ Do not disconnect the lkswage es n
o ot g
connector for the com‐ byV ua
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mand unit before the ir se tee
tho
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self-diagnosis au ac
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⇒ page 25
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take and exhaust

or
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⇒ page 74 .
AG.
4 - ABS control light -K47-

❑ Installation location: of the instrument panel.
Function: ⇒ page 34 .
5 - Brake system control light -K118-

6. Electrical/electronic components and installing locations 9

6 - ESP and ASR control light -K155-

7 - Diagnosis connector
❑ Installation location: Next to the fuse box, under the steering column.
8 - Steering angle sensor -G85-
❑ It may be checked by the “Assisted troubleshooting” with Diagnosis, Measurement and Information Sys‐
tem -VAS 5051A/52-
❑ Installation location: at the steering column between the steering wheel and the steering column switch.
❑ Observe the assembly procedure. AG. Volkswagen
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⇒ page 46 . Volks ot g
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9 - Lateral acceleration sensor -G200- and Lateral tiltingth intensity sensor -G202-
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❑ It can be checked in the function “Assisted troubleshooting” with Diagnosis,
ss Measurement and Informa‐
ce
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tion System -VAS 5051A/52-

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❑ Packed in a case.
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❑ Installation location: at the left seat crossmember, on the floor plate.
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❑ Remove and install ⇒ page 45 .
hole
spec
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10 - Front right wheel rotation sensor -G45- / Left front wheel rotation sensor -G47-
t to the co
tem -VAS 5051A/52-
rrectness of i
❑ Replace ⇒ page 36 .
l purpos
11 - Rear right wheel rotation sensor -G44- / Left rear wheel rotation sensor -G46-
tem -VAS 5051A/52-
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❑ The ABS sensor ring is assembled to the wheel bearing.
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13 - Switch for the ASR / ESP electronic stability program -E256-

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6.3 ABS Bosch 8.2

As from model-year 2011


function “Assisted trou‐
nosis, Measurement
-VAS 5051A/52-
❑ Do not disconnect the
connector for the com‐
mand unit before the
self-diagnosis.
⇒ page 25 .
function “Assisted Trou‐
nosis, Measurement
-VAS 5051A/52-
take and exhaust
valves)
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⇒ page 25 i.sed b ara
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3 - Brake light
sa
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-F- or or
ac
Brake pedals switch -F47-
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⇒ page 74 .
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4 - Brake system control light -K118-

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❑ Installation location: on the instrument panel

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5 - ABS control light -K47-

rrectness of i
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6 - Diagnosis connector
❑ Installation location: Next to the fuse box, under the steering column.
nform
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7 - Rear right wheel rotation sensor -G44- / Left rear wheel rotation sensor -G46-
m
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on in
tem -VAS 5051A/52-

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8 - Rear wheel hub/roller bearing set

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6. Electrical/electronic components and installing locations 11

10 - Front right wheel rotation sensor -G45- / Left front wheel rotation sensor -G47-
tem -VAS 5051A/52-
11 - Centrifuging disc
❑ Only for vehicles with ABS brake.
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Prote AG.
Rep. Gr.45 - Anti-lock Braking System (ABS)
7 Hydraulic unit, servo brake/master

cylinder - Bosch 5.7 (up to model
2011) - Assembly overview
The brake cylinder and the servo brake may be independently
replaced.

⇒ page 15
❑ The following compo‐
nents are checked in the
hydraulic unit ABS hy‐
draulic pump -V64- and
the inlet and exhaust
valves through self-di‐
agnosis
❑ A ABS hydraulic pump -
V64- and the valve block
may not be separated
❑ Remove and install AG. Volkswagen AG d
⇒ page 15 agen oes
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4 - Brake pressure Sensor 1 -
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⇒ page 21
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5 - Brake pipe connection
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❑ Hydraulic unit to to left
spec
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front brake caliper
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❑ Identification in the hy‐
draulic unit “VL”
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❑ Hydraulic unit to right

front brake caliper
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draulic unit “VR”

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❑ Brake master cylinder/floating plunger circuit to the hydraulic unit

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❑ Identification in the hydraulic unit “HZ2”

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❑ Brake master-cylinder/pressure plunger circuit to the hydraulic unit Cop py
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❑ Identification in the hydraulic unit “HZ1”
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❑ For the left rear brake caliper

❑ Identification in the hydraulic unit “HL”
❑ For the right rear brake caliper
❑ Identification in the hydraulic unit “HR”
7. Hydraulic unit, servo brake/master cylinder - Bosch 5.7 (up to model 2011) - Assembly overview 13
11 - Servo brake
❑ On gasoline engines, the required vacuum is taken from the intake manifold
❑ On ??diesel engines, there is a vacuum pump for vacuum transformation
❑ Check the operation:
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– Fully press the brake pedal several times with the engine turned swa(this eliminates any dremaining
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– Hold the brake pedal with average strength at brakings aposition and turn the engine on. A fully operational
u ra
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servo brake may be sensed when the operator's feet is on the pedal (active multiplication).
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– In case of faults, completely replace the servo brake.
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❑ Verify the check valve (in the vacuum hose) ⇒ page 91
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❑ Remove and install ⇒ page 94
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12 - Sealing hole
spec
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❑ To servo-brake
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13 - Hexagon nut
❑ Self-locking
rrectness of i
❑ 28 Nm
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14 - Seal ring
❑ Replace whenever the master cylinder is removed
nf
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15 - Hexagon nut
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❑ Self-locking
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❑ 20 Nm
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16 - Brake cylinder
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❑ Cannot be repaired. In case of fault, replace it completely
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❑ Remove and install ⇒ page 92 C py
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❑ Insert through the brake master cylinder Prote AG.
18 - Sealing plug
❑ Moist with brake fluid and press into the brake master cylinder
19 - Sealing plug
❑ Connection for vacuum hose
20 - Brake fluid reservoir
21 - Cover
22 - Hexagon nut
❑ Self-locking
❑ 20 Nm
23 - Support
24 - Stud
❑ Welded to body
25 - Screw
❑ 8 Nm
26 - Support
27 - Screw
❑ 8 Nm
28 - Hexagon nut
❑ Self-locking

❑ 20 Nm
29 - Stud
❑ Welded to body
7.1 Hydraulic unit connections

7.1.1 Connect the brake pipes for the brake
cylinder pipes (Tandem) to the hydraulic
unit
A - Hydraulic unit to the brake cylinder pressure plunger loop.
- Identification in the hydraulic unit -HZ1-.
B - Hydraulic unit to the brake cylinder floating pressure plunger
loop.
1 - Hydraulic unit for left front brake caliper.
- Identification in the hydraulic unit -VL-.
2 - Hydraulic unit for right front brake caliper.
- Identification in the hydraulic unit -VR-.
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3 - Hydraulic unit to right rear brake caliper.
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- Identification in the hydraulic unit
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4 - Hydraulic unit to left rearssbrake
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- Identification in the hydraulic unit -HL-. pt

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7.2 Control unit and hydraulic unit - remove
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♦ Torque wrench - 5 to 50Nm (socket 1/2") -VAG 1331-

rrectness of i
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♦ Brake pedal actuator -V.A.G 1869/2-
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♦ Repair set of plugs -1H0 698 311 A-
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1- Transport protection for ??valve tubes
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3- Plugs M12
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Prote AG.
Note
♦ After disconnecting the control unit from the hydraulic unit, al‐
ways place the transport protection for valve tubes on the
hydraulic unit.
♦ Hydraulic unit without transport protection are not covered by
warranty.
7.2.1 Removal
WARNING
Brake piping in the hydraulic unit area shall not be bent!
– Disconnect the battery ⇒ Electrical equipment; Rep. Gr. 27 ;

Battery - disconnect and connect .

AG. Volkswagen AG d
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♦ Check whether the vehicle has a coded radio. If so, request
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the anti-theft code before disconnecting the battery earth
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♦ When the battery is reconnected, check the operation of the
h re
vehicle electrical system (radio, clock and electric door and
hole
spec
window locks, etc.) according to the Workshop Manual and/or
es, in part or in w
instructions for use.
t to the co
Gasoline engine/Totalflex
rrectness of i
– Pull the hose from the oil separator and the check valve on the
upper air filter case section.
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– Remove the cover by the points marked with -arrows-.
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Diesel engine:
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– Remove engine bonnet towards the -arrows-.
– Remove the escape gas return valve -1-.

Continuation for all vehicles:
– Disconnect the connector of the Brake pressure Sensor 1 -
G201- -2-.
– Unlock -arrow 3- and disconnect -arrow 1- the connector of

ABS hydraulic unit -N55- .
– Disconnect the Brake pressure Sensor 1 -G201- -2-.
– Press the brake pedal and install the Brake pedal compression
device -VAG 1869/2- .
– Install the bleed hose of the bleed reservoir on the bleed valve
of the left front brake caliper and open the valve.
– Close the front left bleed valve.
– Place a proper amount of non-fraying cloth under the control
unit and the hydraulic unit.
Watch that no brake fluid reaches the contacts.
– Loosen and hang the hydraulic unit brake pipes -1- to the
brake master cylinder.
– Disconnect the remaining brake pipinggfrom
en AGthe
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– Close the brake tubing and screw
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– Unscrew the hexagonal ss nuts -3- and -5- from the control
a
unit/ c
hydraulic unit support.
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– Remove the hydraulic unit along with the control unit.
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– Unscrew the hexagonal nuts -2- and -4- and remove the con‐
ility
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trol unit/hydraulic unit support.
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7.2.2 Installation
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Only remove the plugs from the new ABS hydraulic unit -N55-
t
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when the respective brake pipe is assembled. If the plugs were

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already removed from ABS hydraulic unit -N55- , brake fluid may
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leak to the point that proper ventilation and filling can no longer
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– Install the ABS unit on the support. Prote
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– Installation is performed in the reverse sequence of the re‐

moval.
– Bleeding brake system ⇒ page 85
– Code the ABS control unit -J104- .
Connect the Diagnosis, Measurement and Information System -
VAS 5051A/52- and select the function ⇒ page 4 .
– Code the radio.

Brake piping tightening torques:

ABS Bosch - (5.7)
Positions Component Torque set‐
ting
-1- agBrake
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Tightening torques for fastening the ABS unit and supports:
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ABS Bosch - (5.7)
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Positions Nuts / Screws Torque
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-2 / 4- Screw 8 Nm
-3- Hexagon nut 20 Nm
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7.3 ABS control unit -J104- from the ABS
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hydraulic unit -N55- - Remove and in‐
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7.3.1 Removal
Note
♦ If the ABS control unit -J104- is damaged, it will be necessary

to separate it from ABS hydraulic unit -N55- and merely re‐
place the command unit.
♦ If the ABS hydraulic unit -N55- is damaged, you should replace
it with the ABS control unit -J104- .
ABS Bosch 5.7:

1- ABS control unit -J104-
2- ABS hydraulic unit -N55-
3- Brake pressure Sensor 1 -G201-
4- ABS reflux pump -V39-
– Remove the external screws -1 - nd -6- from the ABS hydraulic

unit -N55- .
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Torx screws should uthonot
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– Carefully remove ABS control unit -J104- from the ABS hy‐
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draulic unit -N55- , pulling it up.
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When removing ABS control unit -J104- , ensure that the valve
es, in part or in w
tubes -1- from the ABS hydraulic unit -N55- -b- are not folded
t to the co
together with electromagnetic coils -2- from the ABS control unit
-J104- -nd-.
rrectness of i
– Cover the electromagnetic coils of the ABS control unit -J104-
with a non-fraying cloth.
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– Check the sealing surfaces of ABS hydraulic unit -N55- for

cleanliness; if necessary, clean with ethyl alcohol using a non-
nform
ercia
fraying cloth.
m
at
om
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While working on the hydraulic system unit sealing surfaces, do
on
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not use files, metal scrapers, sandpapers or similar tools.

in t
or
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ate
If the sealing surface of ABS hydraulic unit -N55- is damaged

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– Check the contact springs -1- from the ABS hydraulic unit -
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N55- ( ABS reflux pump -V39- ) for possible burned and rusty
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No grinding or cleaning of any kind is allowed on the contact

springs, as ABS hydraulic unit -N55- must be replaced together
with ABS control unit -J104- .
– Protect the ABS hydraulic unit -N55- when open, against dam‐
age to the valve tubes, and cover it with a non-fraying cloth.
7.3.2 Installation
When installing ABS control unit -J104- -nd- on the ABS hydraulic
unit -N55- -b-, ensure that the valve tubes -1- are not folded to‐
gether with electromagnetic coils -2-.
– Install ABS control unit -J104- on the ABS hydraulic unit -N55- .
– Press ABS control unit -J104- onto the seating surface of ABS
hydraulic unit -N55- until it engages fully onto the rib on ABS
hydraulic unit -N55- and maintain this position.
– Tighten the center screws, working alternately -1- and -2- until
attaching the ABS control unit -J104- on the ABS hydraulic unit
-N55- .

Use the new screws supplied with the set.

– Install the screws -3- nd -6- and tighten the screws until seating
the ABS control unit -J104- .
WARNING
Torx screws should not be reused.
– Then, alternately tighten the screws.

– Tighten the screws in sequence from -1- nd -6- to the specified
tightening torque.
The hydraulic unit threads used to fasten the control unit must not
be damaged. If the thread is damaged (trouble in tightening the
screws manually or screws not tightened to the specified torque),
replace ABS hydraulic unit -N55- .
– Identify by striking the traced area -arrow-, each ABS hydraulic

unit -N55- on the ABS control unit -J104- .
Note
A ABS hydraulic unit -N55- can only bear 5 assemblies on the

ABS control unit -J104- . After 5 assemblies on ABS control unit
-J104- it must be replaced. n AG. Volkswagen A G do
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7.4 Brake pressure Sensor 1 -G201- - re‐

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move and install

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7.4.1 Removal
spec
t to the co
– Remove the air cleaner or the engine cover according to the

vehicle motorization:
♦ Gasoline engine/Totalflex ⇒ page 17
rrectne
♦ Diesel engine ⇒ page 17

ss
– Pull off connector -3- of Brake pressure Sensor 1 -G201- -2-.

o
cial p
f in
– Place a proper amount of non-fraying cloth under the control

form
mer
unit and the hydraulic unit.

atio
om
– Release brake pipes -1- from the hydraulic unit.

n
c
i
or
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– Close the brake tubing and screw holes with the plugs of Re‐
t
sd
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pair set of plugs -1H0 698 311 A- .

pr
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– Remove the Brake pressure Sensor 1 -G201- .

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7.4.2 Installation
Install by inverting the removal sequence, paying attention to the
following:
– Bleeding brake system ⇒ page 85 .

Tightening torque:
Brake pressure Sensor 1 -G201- 20 Nm
AG. Volkswagen AG d
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spec
t to the co
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mer
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Cop py
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pyri by
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by
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Prote AG.

8 Hydraulic unit, servo brake/brake cyl‐

inder - Assembly overview (Bosch
8.0 / 8.2)
The brake cylinder and the servo brake may be independently
replaced.
WARNING
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gen AG does
swa
Always replace self-locking nuts and screws whichy were Volk sub‐ not
gu
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erm
❑ Remove and install ABS
ab
ility
hydraulic unit -N55- with
ot p
wit
ABS control unit -J104-
, is n
h re
⇒ page 25 .
hole
spec
es, in part or in w
t to the co
V39- and the coupled
valves may not be sep‐
rrectness of i
arated.
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❑ When replacing ABS

hydraulic unit -N55- ,
seal the old part with the
nf
ercia
plugs from the repair set
orm
number ET 1H0 698 311
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A.
o
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or c
❑ Remove and install ABS
thi
te
hydraulic unit -N55- with
sd
iva
o
r
ABS control unit -J104-

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⇒ page 25 .
f
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3 - Brake pipe connection C py
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❑ Hydraulic unit for right py by
co Vo
front brake caliper.
by lksw
cted agen
Prote AG.
draulic unit -VR-.
❑ For the left rear brake
caliper.
draulic unit -HL-.
❑ For the right rear brake
caliper.
draulic unit -HR-.
❑ Hydraulic unit for left front brake caliper.
❑ Identification in the hydraulic unit -VL-.
7 - Brake cylinder connection
❑ Brake cylinder/floating plunger loop for the hydraulic unit.
❑ Identification in the hydraulic unit -HZ1-.
8. Hydraulic unit, servo brake/brake cylinder - Assembly overview (Bosch 8.0 / 8.2) 23
8 - Brake cylinder connection

❑ Brake cylinder/floating plunger loop for the hydraulic unit.
❑ Identification in the hydraulic unit -HZ2-.
9 - Sealing
❑ To the servo brake.
10 - Servo brake
❑ On gasoline engines, the vacuum required is removed from the intake manifold.
❑ On diesel engines, a vacuum pump is installed to create vacuum.
Operation check:
– Press the brake pedal several times until the end with the engine stopped (This eliminates any remaining
vacuum inside the device).
– Now, keep the brake pedal pressed in the braking position with medium force and start the engine. When
the servo brake is working properly, this can be felt with your foot on the brake pedal (the amplification
is active).
❑ In case of faults, replace it completely.
❑ Check valve (in the flexible vacuum tube) ⇒ page 91 .
❑ Separate the brake pedal ⇒ page 72 . lkswage es n
o ot g
byV ua
❑ Disassemble and assemble ⇒ page 94 . ir se
d ran
te
ho eo
ut
11 - Hexagon nut ss
a ra
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❑ Self-locking
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nl
pt
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an
❑ Replace
itte
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ab
❑ 28 Nm
ility
ot p
wit
12 - Seal ring
, is n
h re
❑ Replace
hole
spec
es, in part or in w
13 - Hexagon nut
t to the co
❑ Self-locking
❑ Replace
rrectness of i
❑ 20 Nm
l purpos
14 - Brake cylinder
❑ Cannot be repaired. In case of fault, replace it completely.
nf
ercia
❑ Remove and install ⇒ page 92 . orm

m
atio
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15 - Retaining pin for the brake fluid reservoir

o
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❑ Insert through the brake master cylinder.

thi
te
sd
iva
16 - Sealing plug
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o
❑ Moist with brake fluid and press against brake master cylinder.
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17 - Sealing plug C py
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yri
❑ Connection to flexible vacuum tube. p by
co Vo
by lksw
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18 - Brake fluid reservoir Prote AG.
19 - Plug
20 - Screw
❑ 8 Nm.
21 - Hexagon nut
❑ Self-locking
❑ Replace
❑ 20 Nm

22 - Support
23 - Stud
❑ Stud welded to the body.
24 - Hexagon nut
❑ Self-locking
❑ Replace.
❑ 20 Nm.
25 - Stud
❑ Stud welded to the body.
26 - Support
8.1 Hydraulic unit connections

Connect the brake pipes and the brake cylinder pipes to the hy‐
draulic unit:
A - Hydraulic unit to the brake cylinder pressure plunger loop(14
Nm).
B - Hydraulic unit to the brake cylinder pressure plunger loop (14
Nm). gen AG
. Volkswagen AG
a does
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1 - Hydraulic unit to right rear brake caliper.d by Vo gu
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2 - Hydraulic unit to left rear brake caliper.
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3 - Hydraulic unit for left front brakes caliper.
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nl
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itte
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ab
On the hydraulic system unit:
ility
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, is n
A - Hydraulic unit to the brake cylinder pressure plunger loop.
h re
hole
spec
es, in part or in w
t to the co
B - Hydraulic unit to the brake cylinder floating pressure plunger
loop.
rrectness of i
1 - Hydraulic unit for right front brake caliper.

l purpos
- Identification in the hydraulic unit -VR-.

nf
ercia
2 - Hydraulic unit to left rear brake caliper.

orm
m
atio
- Identification in the hydraulic unit -HL-.

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3 - Hydraulic unit to right rear brake caliper.

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sd
iva
- Identification in the hydraulic unit -HR-.

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4 - Hydraulic unit for left front brake caliper.

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- Identification in the hydraulic unit -VL-.
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rig by
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by lksw
8.2 ABS control unit -J104- on the ABS hy‐
cted agen
Prote AG.
draulic unit -N55- - remove and install

AG. Volkswagen AG d
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SpaceFox, Space Cross, Suran, by
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ol not
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Brake systems - Editionor05.2011
ise ran
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♦ "Torque wrench - 5 to 50 sNm
s
( socket 1/2")" -VAG 1331-
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le
un
pt
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rm
ab
pe
ility
ot
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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♦ Brake pedal compression device -VAG 1869/2-
nform
mercia
a
com
tion in
r
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thi
s
iva
do
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Cop py
t. rig
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pyri by
Vo
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by c lksw
cted agen
Prote AG.
Plug repair set 1H0 698 311 A

After disconnecting ABS control unit -J104- from the ABS hy‐
draulic unit -N55- , always fit on the hydraulic unit the valve tube
transport protection.
Hydraulic unit without the transport protection are not covered by
warranty.
1- Valve tube transport protection.
2- M 10 Plugs.
3- M 12 Plugs.

8.2.1 Remove
Installation location:
A ABS control unit -J104- is fastened to ABS hydraulic unit -N55-
and is located in the engine compartment, right side -arrow-.
WARNING
The brake pipes in the hydraulic unit area must not be bent.
– Observe coding on vehicles equipped with code radio. Re‐

quest coding if necessary.
– Disconnect the battery ⇒ Electrical system; Rep. Gr. 27 ;
Starter, alternator, battery .
3 cylinders, injection engine:
. Volkswage
– Disconnect the vacuum
wage hoses from the upper
n AG n AG d
oes air filter case
section. Volks not
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4 cylinders, injection engine:

pe
ility
ot
wit
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– Pull the hose from the oil separator and the check valve on the
h re
upper air filter case section.

hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia

m
a
com
3-cylinder diesel engine:

tion in
r
te o
– Pull the engine cover up and away from the fittings.

thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
– Remove the intake hose -1-.

4-cylinder diesel engine with injector pump unit:
– Remove hose -1- and intake tube -2- ⇒ Engine; Rep. Gr. 23 ;
Supply system - fuel injection (diesel) .
or:
lkswage es n
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byV ua
d ran
ir se tee
o
– Remove flexible
au suction tube-1- and Motor for intake manifold or a
th
valve -V157-ss-2- ⇒ Engine; Rep. Gr. 23 ; Supply system - fuel c
ce
le
injection (diesel) .
un
pt
an
d
itte
4 cylinders, diesel engine with distribution injector pump:

y li
erm
ab
ility

ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Remove the escape gas return valve -1-.

ss o
Continuation for all vehicles:

cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Push down the connector safety lock -arrow- down.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
– Release the connector for ABS controlss unit -J104- -arrow- and
remove it by pulling it forward
ce
e
nl
pt
du
an
itte
– Place the Brake pedal compression device -VAG 1869/2- .
y li
erm
ab
– Press the brake pedal with the Brake pedal compression de‐
ility
ot p
vice -VAG 1869/2- should already be positioned.
wit
, is n
h re
hole
– Close the left front venting plug.
spec
es, in part or in w
– Place the hose from the bleeding reservoir over the left front
t to the co
brake caliper plug and open the plug.
rrectness of i
l purpos
– Place a sufficient amount of non-fraying cloths under ABS

control unit -J104- and the ABS hydraulic unit -N55- .
nform
mercia
at
WARNING
om
ion
c
in t
or
Make sure no brake fluid get on the contacts for ABS control
his
ate
unit -J104- .
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Loosen and hang the-A-B-1-2-3-4- brake pipes from the break

cylinder hydraulic unit.
Note
To avoid excessive leaking of brake fluid, use the exhaust valve

protection cover to seal brake piping -A and B-.
– Close the brake pipes and threaded holes with plugs from the
repair set number 1H0 698 311 A.
– Remove the hexagonal nut -1- of the ABS control unit -J104- /
ABS hydraulic unit -N55- .
– Remove the ABS control unit -J104- / ABS hydraulic unit -
N55- , pulling it up -arrow-.
– Remove the command device / hydraulic unit support by re‐
moving screws -2-.
There is no need to remove the lower ABS support by removing
nuts -3-.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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8.2.2 Install or eo
h
aut ra
ss c
ce
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un
pt
an
Note
d
itte
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rm
ab
pe
ility
♦ Only remove the plugs from the new hydraulic unit when the
ot
wit
respective brake pipe is assembled.
, is n
h re
hole
♦ If the plugs were already removed from the hydraulic unit, the
spec
brake fluid may leak to the point that proper venting and filling
es, in part or in w
t to the co
can no longer be ensured.
– Install the ABS unit on the support.
rrectness of i
– Resume the installation in the removal reverse order.
l purpos
– Remove the Brake pedal compression device -VAG 1869/2- .
nform
ercia

m
– Code ABS control unit -J104- .
a
com
tion in
Connect the Diagnosis, Measurement and Information System -
r
te o
VAS 5051A/52- and select the function ⇒ page 4 . thi

s
iva
do
r
rp
– Code the radio.

um
fo
en
ng
t.
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Brake piping tightening torques:
Co
Cop py
t. rig
gh ht
ABS Bosch - (8.0 / 8.2) pyri by
Vo
o
by c lksw
cted
Brake pipes in the ABS set: -A-B-1-2-3-4-
agen
Prote AG.
Threads M 10 x 1 14 Nm
Threads M 12 x 1 14 Nm

Tightening torques for fastening the ABS unit and supports:

G. Volkswagen
ABS waBosch
gen A - (8.0 / 8.2)
AG do
es n
Volks ot g
Positions
se
d by
Nuts / Screws Torque ua setting
ran
i tee
or
th-1-
au Hexagon nut 20 Nmor a
ss c
-2- Screw 8 Nm
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
8.2.3 Remove the ABS control unit -J104-
nform
ercia
from the ABS hydraulic unit -N55-

m
at
om
io
ABS Bosch 8.2 command unit:
n
c
in t
or
his
ate
do
riv
1 - Command device
p
cum
for
en
g
2 - Hydraulic unit
n
t.
yi Co
Cop py
3 - Reflux pump
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Remove the ABS command unit.
– Remove exterior E5 Torx screws -1 to 4- from the hydraulic

unit.
WARNING

It is forbidden to separate the reflux pump from the hydraulic
unit.
– Carefully remove the command device from the hydraulic unit,

pulling it up.
When removing the command equipment, be sure that the valve

tubes -1- from the hydraulic unit -B- are not folded together with
electromagnetic coils -2- from command equipment -A-.
– Cover the command equipment electromagnetic coils -A- with AG. Volkswagen AG d
a non-fraying cloth. agen oes
olksw not
V gu
by ara
– Check the sealing surfaces of the hydraulic unit for cleanli‐
rised
nte
ness; if necessary, clean with ethyl alcohol using a lint-free
aut
ho eo
ra
cloth. ss c
ce
e
nl
While working on the hydraulic system unit sealing surfaces, do
pt
du
an
itte
not use files, metal scrapers, sandpapers or similar tools.
y li
erm
ab
If the sealing surface of the hydraulic unit is damaged (scratches
ility
ot p
or signs of wear), replace the hydraulic unit for the brake system.
wit
, is n
h re
hole
spec
– Check contacts -1- on the hydraulic unit (reflux pump) for pos‐
es, in part or in w
sible burn and rust spots.
t to the co
No work for grinding or cleaning the contacts is allowed due to
the hydraulic unit being replaced along with the command device.
rrectness of i
– When open , protect the hydraulic unit against damage to the
l purpos
valve tubes, covering it with a non-fraying cloth.
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
8.2.4 Install ABS control unit -J104- on the

um
for
en
ng
t.
ABS hydraulic unit -N55-
yi Co
Cop py
t. rig
gh ht
Upon installing command device -A- from hydraulic unit -B-, en‐ pyri by
Vo
o
by c
sure that the valve tubes -1- are not folded together with electro‐
lksw
cted agen
Prote
magnetic coils -2-.
AG.
– Install the command device on the hydraulic unit.

– Press the command device onto the seating surface of the
hydraulic unit until it is fully seated onto the rib of the hydraulic
unit and maintain this position.

AG. Volkswagen AG d
agen oes
ksw
by
Vol SpaceFox, Space Cross, not
gSuran,
ua Suran Cross, Sportvan 2006 ➤
d
rise ran
te Brake systems - Edition 05.2011
ho eo
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c
Use the screws “Torx”
ss new supplied together.
ce
e
nl
pt
du
– Install the screws -1 and 2- and tighten until the command de‐
an
itte
y li
vice is seated.
erm
ab
ility
ot p
wit
WARNING
, is n
h re
hole
spec
es, in part or in w
t to the co
– Then, tighten screws -3 and 4-.
rrectness of i
– Tighten the screws in sequence from -1-2-3-4- to a torque of
16 Nm.
l purpos
The hydraulic unit threads used to fasten the command device

must not be damaged. If the thread is damaged (trouble in tight‐
nform
ercia
ening the screws manually or screws not tightened to the speci‐

m
at
fied torque), replace hydraulic system unit.
om
ion
c
in t
or
– Identify by the pulsing in the indicated area (hatched)
his
ate
-arrow-, each assembly of the hydraulic unit with the command
do
priv
c
device.
um
for
en
ng
t.
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op py
WARNING
t. C rig
gh ht
pyri by
Vo
o
by c lksw
The hydraulic unit supports only 5 assemblies on the command cted agen
Prote AG.
unit. The command unit should be replaced after 5 assemblies.
Install the ABS command unit.
9 Fault indication via control lamps

9.1 Control lamps
Item Nomenclature
-1- ABS control light -K47- .
-2- Brake system control light -K118- .
-3- ESP and ASR control light -K155- .
ABS control light -K47- :
♦ If the ABS control light -K47- for ABS -1- does not go off after
the ignition is turned on and after the inspection is over, the
fault may have the following causes:
-nd- the voltage supply is below 10 Volt.
-b- there is a fault in the ABS.
In the case of a fault in the ABS -b-, the antilock braking system
is turned off, while the conventional brake system remains fully
operational.
-c- there was a temporary fault in the speed sensor from the the
last time the vehicle was started. wage
e ks s no
Vol t gu
In the case of speed sensor -c- nd ABS controledlight by -K47- auto‐ ara
matically goes off after the vehicle is started and
horis at a speed higher nte
eo
than 20 km/h. sa
ut ra
c
s
-d- there is an interruption in the connection between the instru‐
ce
e
nl
pt
du
ment panel and ABS control unit -J104- . ⇒ Electrical diagrams,

an
itte
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diagnosis of electrical faults and installation locations .

erm
ab
ility
ot p
ABS control light -K47- and Brake system control light -K118- .
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
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thi
te
sd
iva
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rp
cu
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m
f
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

♦ If the ABS control light -K47- for ABS -1- turns off, while Brake
system control light -K118- for brake system -2- remains on,
the error may have the following causes:
-A-: the parking brake is actuated.
-B-: the brake fluid level is too low.
-C-: failure in the activation of Brake system control light -K118-
lkswagen AG
AG. Vodiagrams,
for the brake system. ⇒swElectrical diagnosis of electri‐
agen does
cal faults and installation
by
Vol
k
locations not
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♦ In case the ho ABS control light -K47- of ABS -1- and Brake
ri tee sys‐
ut o
tem control
ss
a light -K118- for brake system -2- are switchedr aon,
c
this means that ABS system and EBV (electronic brake force
ce
le
un
distribution) system failed.
pt
an
d
itte
y li
erm
ab
WARNING
ility
ot p
wit
is n
h re
After ABS control light -K47- from the ABS and Brake system
ole,
control light -K118- from the brake system turn on, the rear
spec
wheels may lock early during braking.
t to the co
ESP and ASR control light -K155- :
rrectne
♦ If the ESP and ASR control light -K155- for the stabilization
ss
program, ASR/ESP -3- does not go off after the ignition is
o
cial p
f
turned on and after the inspection is over, the fault may have
the following causes: inform
mer
atio
-nd- Short-circuit to positive in Switch for the ASR / ESP electronic

om
stability program -E256- .

c
i
or
n thi
te
sd
-b- A fault in switching the ESP and ASR control light -K155- for
iva
o
r
the stabilization program, ASR/ESP ⇒ Electrical diagrams, diag‐

p
cum
r
fo
nosis of electrical faults and installation locations

en
ng
t.
yi Co
op
-c- The Switch for the ASR / ESP electronic stability program -
C py
ht. rig
E256- . rig ht
py by
co Vo
by lksw
There is a fault exclusively related to the ASR/ESP. The vehicle's
cted agen
Prote AG.
ABS/EDS and EBV safety systems remain fully operational ⇒
Refer to the fault memory.
If the ESP and ASR control light -K155- for the ASR/ESP stabili‐
zation program blinks during the drive, then the ASR or ESP
system is in adjustment mode.
9. Fault indication via control lamps 35

10 ABS system components on the front

and rear axles - remove and install
AG. Volkswagen AG d
agen oes
lksw not
10.1 ABS system components on the front axle - remove and install Vo gu
by ara
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1 - Wheel roller bearing case s
ce
le
un
pt
2 - Hexagon socket head
an
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itte
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screw erm
ab
ility
❑ 8 Nm
ot p
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is n
3 - ABS speed sensor
h re
ole,
spec
❑ It is checked by means
of self-diagnosis.
t to the co
❑ Before installing the
sensor, clean the inter‐
nal hole surface and
rrectne
coat it with Lubricating
putty -G 000 650-
s
around the sensor. Re‐
s o
cial p
fer to the ⇒ Chemical
f in
Materials Manual .
form
mer
❑ remove and install
atio
m
⇒ page 36 .
o
n
c
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4 - Cover plate
t
sd
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pr
c
5 - Hexagonal head screw
um
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en
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❑ 10 Nm
t.
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Cop py
t.
6 - Wheel hub with wheel bear‐
rig
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ings cop Vo
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cted agen
❑ ABS sensor ring is as‐ Prote AG.
sembled in the wheel
hub.
❑ Remove and install ⇒
Running gear, ??
axles, ??steering; Rep.
Gr. 40 ; Front suspen‐
sion .
7 - Brake disc
8 - Screw
❑ 8 Nm
10.1.1 Front axle speed sensor - remove and

install
10.1.2 Removal
– Lift the vehicle.

– Pull off connector -2- from the speed sensor cable and from
the speed sensor.
– Loosen the screw -1- from the wheel roller bearing case.
– Remove the ABS speed sensor from the wheel roller bearing
case.
For easier viewing, the brake disc is represented as removed.
10.1.3 Installation
– Before installing the speed sensor, clean the internal hole sur‐
face and coat with Lubricating putty -G 000 650- around the
sensor. Refer to the ⇒ Chemical Materials Manual .
– Place the speed sensor in the wheel roller bearing case and
tighten the screw to 8 Nm.
– Connect the speed sensor to the speed sensor cable.
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wage oes
– Turn the steering wheel completely to the yV
olleft
ks and to the right not
gu
and control the space available for ithe
se speed sensor cable.
d b ara
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ut
10.2 Bosch 5.7 front speed sensor cables - ss
a ra
c
remove and install
ce
le
un
pt
an
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itte
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rm
ab
pe
ility
♦ Harness repair set -VAS 1978-
ot
wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
10.2.1 Removal
r
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thi
s
iva
do
– Note the coding in vehicles with code radio equipment, request

r
rp
cum
fo
such coding if necessary.

en
ng
t.
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– Disconnect the battery ⇒ Electrical system; Rep. Gr. 27 ; Cop py
t. rig
Starter, alternator, battery . gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
10. ABS system components on the front and rear axles - remove and install 37
AG. Volkswagen AG d
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SpaceFox, Space Cross, Suran, Suran Cross, Sportvand by
V
2006 ➤ gu
ara
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Brake systems - Edition 05.2011 horis
eo
aut ra
ss c
– Unlock and disconnect command unit -arrow 1- and pull it
ce
e
nl
-arrow 2-.
pt
du
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itte
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erm
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ility
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
– Release the multiple connector cover cap with a screwdriver
and remove it.
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Cop py
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Prote AG.
– Unlock the secondary lock (purple) with a small screwdriver in

the arrow direction.
10.2.2 ABS Bosch 5.7, connector -T42-

Contact assignment for connector -T42- ABS control unit -J104-
⇒ Electrical diagrams, diagnosis of electrical faults and installa‐
tion locations .

– With an extractor from the Harness repair set -VAS 1978- pull
out the respective contacts.
– Disconnect the connector from the speed sensor cable as well
as the speed sensor.
olkswagen AG
ag en AG. V
– Also disconnect theVoconnector
lksw -1- in vehiclesdowith
es n the brake
ot g
pad wear indicator.
ed by ua
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or
– Disengageauthe
th support cable -2-. eo
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– Remove the defective speed sensor cable and replace with a
ce
le
un
pt
new cable.
an
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spec
es, in part or in w
t to the co
– Fasten the speed sensor cable in the locations indicated by
the -arrows-. rrectness of i
l purpos
WARNING
nform
ercia
• Ensure that the speed sensor cable at point -A- passes

behind the hydraulic brake lines and that the same at point
m
a
com
ti
-B- passes in front of the hydraulic brake pipe.

on in
r
te o
thi
s
iva
do
– Place the brake pad wear indicator connector on the suspen‐

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rp
cum
fo
sion support.
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ng
t.
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op
– Insert the contact in the plug. C py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.
– Push to the stop the individual cable insulation with the as‐
sembly tool from the Harness repair set -VAS 1978- .
– Lock the contacts with the secondary lock and place the mul‐
tiple connector cover cap.
10.3 Bosch 8.0 / 8.2 front speed sensor ca‐

bles - remove and install
10.3.1 Removal
Starter, alternator, battery .
– Unlock the connector for ABS control unit -J104- pushing the
-arrow-.
AG. Volkswagen AG d
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olksw not
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d by ara
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or eo
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aut ra
– Release the connector
ss for ABS control unit -J104- -arrow- and c
ce
remove it by pulling it forward.

e
nl
pt
du
an
itte
– Release the multiple connector cover cap with a screwdriver

y li
erm
ab
and remove it.

ility
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Contact assignment for the 38-pin connector -T38- / ABS control

, is n
h re
unit -J104- ⇒ Electrical diagrams, diagnosis of electrical faults

hole
and installation locations

spec
es, in part or in w
t to the co
– With an extractor from the Harness repair set -VAS 1978- pull
out the respective contacts.
– Disconnect the connector from the speed sensor cable as well
rrectness of i
as the speed sensor.

l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
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t.
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Cop py
t. rig
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by c lksw
40
cted agen
Prote
Rep. Gr.45 - Anti-lock Braking System (ABS)
AG.
– Also disconnect the connector -1- in vehicles with the brake

pad wear indicator.
– Disengage the support cable -2-.
– Remove the defective speed sensor cable and replace with a
new cable.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
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ed
ris nte
ho eo
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c
– Fasten the speed sensor cable in the locations indicated by ss
ce
e
the -arrows-.
nl
pt
du
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itte
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ab
WARNING
ility
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• Ensure that the speed sensor cable at point -A- passes
h re
hole
behind the hydraulic brake lines and that the same at point
spec
-B- passes in front of the hydraulic brake pipe.
es, in part or in w
t to the co
– Place the brake pad wear indicator connector on the suspen‐
rrectness of i
sion support.
l purpos
– Insert the contact in the plug.

– Lock the contacts with the secondary lock and place the mul‐
nform
ercia
tiple connector cover cap.

m
at
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ate
10.4 ABS system components on rear axle

do
priv
cum
or
(vehicles with drum brakes) - remove

f
en
ng
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and install Cop py
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cted
WARNING
agen
Prote AG.
Always replace self-locking nuts and screws which were sub‐

jected to angular torque.
1 - Axle beam
screw
❑ 8 Nm
❑ Shall be checked by
means of self-diagnosis
❑ Before installing the
sensor, clean the inter‐
nal hole surface and
coat it with Lubricating
putty -G 000 650-
around the sensor. Re‐
fer to the ⇒ Chemical
Materials Manual .
❑ Drum brake
⇒ page 42 .
4 - Brake tube
5 - Axle end
6 - Parking brake cable
❑ With spring-washer
8 - Screw
9 - Brake drum
❑ Brake drum diameter,
200 mm.
❑ Wear limit 201.5 mm.
❑ Before removing the
brake drum, you must gen AG. Volkswagen AG
does
pull the brake backVol
ksw
a
not
⇒ page 62 . ed by gu
ara
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❑ Clean carefully
ut
ho and eo
ra
check sfor
s wear, damages, dimensional precision and braking
a c surface with no apparent damages.
ce
e
nl
10 - Cover
pt
du
an
itte
❑ Pull out and fit ⇒ Running gear, ??axles, ??steering; Rep. Gr. 42 ; Rear suspension .
y li
erm
ab
ility
11 - ?Rifled nut
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❑ self-locking
h re
hole
❑ Replace
spec
es, in part or in w
12 - Wheel hub with wheel roller bearing and rotor

t to the co
❑ Always replace completely.

❑ Remove and install ⇒ Running gear, ??axles, ??steering; Rep. Gr. 42 ; Rear suspension .
rrectness of i
13 - Caliper body with brake shoes

l purpos
❑ Before removing the brake drum, stand back the brake ⇒ page 62 .
nf
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atio
10.4.1 Speed sensor on rear axle (drum brake)

om
n in
c
- remove and install

or
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Removal:
o
r
rp
cu
o
m
f
en
ng
– Lift the vehicle.

t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Pull off connector -1- from the speed sensor cable, as well as
the speed sensor.
– Loosen the screw -2- from the axle end.
– Disconnect the speed sensor from the axle end.
Installation:
– Before installing the speed sensor, clean the internal hole sur‐
face and coat with Lubricating putty -G 000 650- around the
sensor. Refer to the ⇒ Chemical Materials Manual .
– Place the speed sensor in the axle tip hole and tighten the
screw to 8 Nm.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
o
10.4.2 Rear speed sensor cables - remove and th eo
au ra
ss c
install
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
Removal:
c
in t
or
his
te

a
do
riv

p
cum
for
en
g

n
t.
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op
Starter, alternator, battery . C py
t. rig
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yri by
– Disconnect the connector from the speed sensor cable as well cop Vo
by lksw
as the speed sensor. cted agen
Prote AG.
– Remove the back door sill lining.

– Pull back the carpeting around the seat area ⇒ Body - internal
mountings; Rep. Gr. 70 ; Lining / Insulation .
– Remove the rubber caul -1- and pull the revolution sensor ca‐
ble -2- inward of inner compartment.
– Cut the speed sensor cable between -arrows- -A- and -B- us‐
ing the insulating pliers from the Harness repair set -VAS
1978- and remove the defective section -2- of cable.
Installation:
– Insert the new speed sensor cable.
olkswagen AG
en AG. V
– Strip 15 mm of the cable stub with the insulating pliers and turn olkswag does
not
the stripped cable halfway. ed
by
V gu
ara
is nte
or
– Connect the speed sensor cable using a cable fastener
au
th from eo
ra
the Harness repair set -VAS 1978- . ss c
ce
le
un
pt
– Connect the speed sensor to its corresponding cable connec‐
an
d
itte
tor.
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erm
ab
ility
When installing the speed sensor cable, make sure it is not twis‐
ot p
ted in the wheel housing.
wit
is n
h re
ole,
spec
t to the co
– Fasten the rubber caul -1-.
rrectne
– Fold down floor covering in area of bench seat.
– Install the rear door sill lining ⇒ Body - internal mountings;
ss o
Rep. Gr. 70 ; Lining / Insulation .

cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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pr
cum
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fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

11 ESP system components - remove

and install
11.1 Lateral tilting intensity sensor -G202-

and Lateral acceleration sensor -G200-
- remove
lksw
agen and install
AG. Volkswagen AG d
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The Lateral ris
edtilting intensity sensor -G202- and Lateral
b ara
nte accelera‐
tion sensor
utho -G200- are packed in a case and are located
eo
ra
on the
seatsscross
a member under the carpet. c
ce
e
nl
11.1.1 Removal
pt
du
an
itte
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erm
ab
– Remove the left seat ⇒ Body - internal mountings; Rep. Gr.
ility
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72 ; Seat framework .
wit
, is n
h re
– Remove the left door sill lining ⇒ Body - internal mountings;
hole
Rep. Gr. 70 ; Lining / Insulation .
spec
es, in part or in w
– Pull away the floor carpet until Lateral tilting intensity sensor -
t to the co
G202- and Lateral acceleration sensor -G200- become free.
– Disconnect the connector of the Lateral tilting intensity sensor
rrectness of i
-G202- and Lateral acceleration sensor -G200- .
l purpos
– Loosen the two fastening nuts -1-.

– Remove the Lateral tilting intensity sensor -G202- and Lateral
nform
ercia
acceleration sensor -G200- .

m
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ion
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or
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ate
do
priv
cum
for
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Cop py
t. rig
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Vo
co lksw
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cted agen
Prote AG.
11.1.2 Installation
WARNING
Very strong vibrations may damage the Lateral tilting intensity

sensor -G202- and Lateral acceleration sensor -G200- .
– Installation is performed in the reverse sequence of the re‐

moval.
When installing the Lateral tilting intensity sensor -G202- and Lat‐
eral acceleration sensor -G200- , correct, effortless seating on the
fittings must be guaranteed.
Under no circumstances, Lateral tilting intensity sensor -G202-
and Lateral acceleration sensor -G200- should be positioned
forcefully through attaching nuts.
Tightening torque:
Fastening nuts for the Lateral tilting intensity sensor 6 Nm
-G202- and Lateral acceleration sensor -G200-
11. ESP system components - remove and install 45

11.2 Steering angle sensor -G85- - remove

and install
The steering angle sensor is installed between the steering wheel
and the steering column switch.
11.2.1 Removal olk swage

es n
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byV ua
– Position the wheels in a straight angle. rised ran
tee
tho
or
– Remove the Airbag unit, if there is anyone,
ss
au
and the steering ac
wheel. ⇒ Running gear, ??axles, ??steering; Rep. Gr. 48 ;
ce
e
nl
Steering .
pt
du
an
itte
y li
– Remove the Steering angle sensor -G85- .
erm
ab
ility
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11.2.2 Installation
wit
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hole
– Install the Steering angle sensor -G85- and carry out the basic
spec
adjustment.
es, in part or in w
t to the co
– Carry out basic adjustment with the Diagnosis, Measurement
and Information System -VAS 5051A/52- in the function “As‐
sisted troubleshooting”.
rrectness of i
– Connect the Diagnosis, Measurement and Information Sys‐
l purpos
tem -VAS 5051A/52- and advance until the is displayed “Func‐

tion/component selection”.
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Prote AG.

46 – Brakes - Mechanical system

1 Front wheel brake wa-gerepair
n AG. Vo lkswagen AG
does
olks not
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1.1 Front wheel
ss brake (FS ll) - assembly au ra
c
overview
ce
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nl
pt
du
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itte
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erm
ab
ility
Note
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♦ To draw the braking fluid from its reservoir, always use the
hole
spec
Brake filling and bleeding equipment -VAS 5234- or the -V.A.G
es, in part or in w
1869/4- .
t to the co
♦ Before removing the brake caliper or removing a hose, install
the Brake pedal compression device -VAG 1869/2- .
rrectness of i
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1 - Brake disc
❑ Thickness: 18 mm
nform
ercia
❑ Wear limit: 16 mm
m
at
om
io
❑ Always replace both
n
c
in t
r
discs on the same axle

o
his
ate
❑ In order to remove, first
do
priv
c
loosen the brake caliper
um
for
en
ng
❑ Maximum disk bumping

t.
yi Co
op
0.03 mm C py
t. rig
gh ht
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❑ Maximum disk bumping p by
o Vo
by c
+ bearing 0.11 mm
lksw
cted agen
Prote AG.
2 - Screw
❑ 8 Nm
3 - Brake pads
❑ Thickness: 12 mm,
brake pad with larger
surface is installed on
the outer side
❑ With wear indicator
(available according to
the vehicle version, limit
2 to 3 mm)
❑ Wear limit with rear
plate: 7 mm
❑ Check the thickness
⇒ Maintenance ; Book‐
let ;
pads on the same axle
⇒ page 48
❑ When replacing the
brake pad, do not re‐
move the brake hose
4 - Brake caliper
❑ Repair ⇒ page 76
1. Front wheel brake - repair 47

5 - Lower sleeve
6 - Lower bushing
7 - Lower spacer sleeve
8 - Lower internal hex head screw
❑ 25 Nm
9 - Air duct
10 - Hexagon screw
❑ 10 Nm
11 - Upper hexagon hex head screw
❑ 25 Nm
12 - Upper spacer sleeve
13 - Upper bushing
14 - Upper sleeve
15 - Fastening sleeve
16 - Brake hose with annular nozzle and hollow screw
❑ 35 Nm
. Volkswagen AG
wa gen AG d
17 - Wheel hub olks
oes
not
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ara
ris ⇒ Frame; Rep. Gr. 40 ; Wheel roller bearings
ed
nte - replace
tho eo
18 - Hexagon screw
ss
au ra
c
❑ 10 Nm
ce
le
un
pt
an
d
itte
19 - Cover plate
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erm
ab
20 - Wheel roller bearing case

ility
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is n

h re
ole,
❑ Before installing the sensor, clean the hole inner surface and apply Lubricating putty -G 000 650- around
spec
the sensor
t to the co
22 - Hexagon socket head screw

❑ 8 Nm
rrectness
1.2 Brake pads (FS II) - remove and install

o
cial p
f inform

mer
atio
m

o
n
c
i
or
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te
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pr
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Cop py
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cted agen
Prote AG.
48 Rep. Gr.46 - Brakes - Mechanical system

♦ Plunger resetting device -T10145-
lkswage es n
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byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
le
un
pt
an
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itte
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1.2.1 Removal
rm
ab
pe
ility
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h re
Note
hole
spec
es, in part or in w
While removing, identify the brake pads that will be reused. Install
t to the co
them at the same place in order to avoid creating different braking
action!
rrectness of i
– Remove the wheels.
l purpos
– For vehicles with brake pad wear indicator, disconnect the

connector -1-.
nform
ercia
– Remove the cover caps.

m
a
com
tion in
r
te o
thi
s
iva
do
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cum
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Loosen the upper and lower screws -arrows- from the brake
caliper and pull them out.
– Remove the brake caliper and wire it, so that the brake caliper
weight does not tension nor damage the brake hose.
– Remove the brake pads.
Only use alcohol for cleaning the brake cylinder.
1.2.2 Installation
Prior to pressing the plungers, collect the brake fluid from the
reservoir into a bottle, as it might leak and cause damages in case
it circulates during this interval.
of the brake caliper and open the valve.

– Press the plunger with the Plunger resetting device -T10145- .

– Close the valve and remove the bleed bottle.
– Install the brake pads.
Note
The brake pad with the larger surface is installed on the outer side!
– Install the brake caliper with the pads in the wheel bearing
case by placing the lower portion at first -arrow-.
– The brake caliper pin shall be behind the wheel bearing case
guide! n AG. Volkswagen AG do
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d ran
ir se tee
tho
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ss
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ility
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– Loosen the upper and lower screws -arrows- at the wheel
ole,
spec
bearing case with 25 Nm.
t to the co
– On vehicles with brake wear indicator, connect the connector.
– Install the wheels. rrectne
Note
ss o
cial p
f i
♦ After each brake pad replacement, repeatedly press the brake

nform
pedal with force while the vehicle is parked, so that the brake
mer
pads perfectly seat for operation.

atio
om
n
c
♦ After replacing the brake pads, check the brake fluid level.
or
n thi
te
sd
iva
o
pr
cum
r
fo
1.3 Brake caliper (FS II) - remove and install

en
ng
t.
yi Co
op py
Special tools and workshop equipment required t. C rig
gh ht
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Vo
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by
cted agen
Prote AG.

AG. Volkswagen
n AG do
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olks ot g
♦ Torque wrench - 5 to 50Nm (socket
ed
by
V
1/2") -VAG 1331- ua
ran
oris tee
th or
au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
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atio
om
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thi
te
sd
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en
ng
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Cop py
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Vo
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by
1.3.1 Removal
cted agen
Prote AG.
Note
action!

connector -1-.

– Loosen the upper and lower screws -arrows- from the brake
caliper and pull them out.
– Remove the brake pads. agen
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– Loosen the upper and lower screws -arrows- at the wheel

bearing case with 25 Nm.
– Install the wheels.
Note

1.4 Front wheel brake (FS ll) - Assembly

overview
Note
♦ To draw the braking fluid from its reservoir, always use the
Brake filling and bleeding equipment -VAS 5234- or the -V.A.G
1869/4- .
♦ Before removing the brake caliper or removing a hose, install
the Brake pedal compression device -VAG 1869/2- .
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3 - Brake pads
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pads on the same axle
⇒ page 55
❑ When replacing the
brake pad, do not re‐
move the brake hose
4 - Brake caliper
❑ Repair ⇒ page 79
5 - Guide pin
❑ 30 Nm
6 - Cover cap
7 - Fastening sleeve
8 - Brake hose with annular nozzle and hollow screw
❑ 35 Nm
9 - Wheel hub
❑ Remove and install ⇒ Frame; Rep. Gr. 40 ; Wheel roller bearings - replace
10 - Hexagon screw
❑ 10 Nm
11 - Cover plate
12 - Wheel roller bearing case
❑ Before installing the sensor, clean the hole inner surface and apply Lubricating putty -G 000 650- around
sensor


❑ 8 Nm
1.5 Brake pads (FS III) - remove and install

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– Loosen the two guide pins -arrows- from the brake caliper and
pull them out.
– Remove the brake caliper and wire it, so that the brake caliper
weight does not tension nor damage the brake hose.
– Remove the brake pads. AG. Volkswagen AG d
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– Loosen the two guide pins -arrows- at the wheel bearing case
with 30 Nm.
Note

1.6 Brake caliper (FS III) - remove and in‐

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1.6.1 Removal
Note
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– Install the brake hose.

Note

guide!
– Loosen the two guide pins -arrows- at the wheel bearing case
with 30 Nm.
Note
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discs.
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Position the vehicles so that the brake disc wear indicators (visual
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Note
If the front brake disc wear indicator markings (visual check) can‐
not be viewed due to wheel design, the wheels must be removed.
Checking conditions of front brake disc wear:

1- Wear indicators -1- and -2- are visible:
The brake discs need not be replaced.
2- Only wear indicator -2- is visible:
The brake discs do not require replacement, but pay attention to
the next change.
3- No brake disc wear indicator is visible.
Replace the brake discs.
Remove and install the front brake discs.

1.7.2 Vehicles with steel wheel
Note
In order to view the brake disc wear indicators

gen AG (visual ncheck)
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Checking conditions of front brake disc wear:

1- Wear indicators -1- and -2- are visible:
The brake discs need not be replaced.
2- Only wear indicator -2- is visible:
The brake discs do not require replacement, but pay attention to
the next change.
3- No wear indicator is visible on the brake disc
Replace the brake discs.
Remove and install the front brake discs.

2 Rear wheel brake (drum brake) - re‐

pair
2.1 Brake drum - Assembly overview
Note
♦ After replacement of the wheel brake cylinder, brake and pad

support, release the parking brake and press the brake pedal
with force while the vehicle is parked, so that the pads correctly
seating for operation.
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1 - Spring plate
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pression spring and turn
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2 - Compression spring
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3 - Brake shoe with parking

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brake lever
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⇒ page 63
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❑ Adjust the parking brake

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⇒ page 68
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❑ Lubricate the support

points with the Grease -
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6 - Drawspring
7 - Brake shoe
⇒ page 63
❑ Minimum pad thickness
2.5 mm
❑ Check the thickness ⇒
Maintenance with Accu‐
racy
Pads are also supplied without
brake shoes

8 - Sealing cap
❑ Remove to check brake pad thickness
9 - Elastic pin
10 - Brake support
❑ 8 Nm
12 - Rear wheel brake cylinder
❑ Check the sealing ⇒ pagee63n AG. Volkswagen AG ag does
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– If there is brake fluid in the seal caul, replace the brake cylin‐
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2.2 Brake shoes - remove and install

2. Rear wheel brake (drum brake) - repair 63

♦ Hook -3438-
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– Remove the brake drum.
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⇒ Item 2 (page 62) .
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– Disengage the lower positioning spring ⇒ Item 5 (page 62) .
– Release the parking brake cable.
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– Remove the brake shoes between the wheel hub and the
l purpos
brake support.
– Fasten the brake shoes in a vise.
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– Remove the drawspring -1- from the wedge -2-.
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– Remove the upper positioning spring -3- with Hook -3438- .

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– Remove the return spring -1- with Hook -3438- .

– Remove the operating rod -2- and the wedge -3- from the
brake shoe.
Solely use alcohol for cleaning the brake system.

2.2.2 Installation
– Engage the support spring -1- with Hook -3438- on the oper‐
ating rod -2-.
– Simultaneously place the wedge -3-.
Assembly position: the protuberances -arrow- must remain visible
when installing.
– Place the brake shoe with the lever on the operating rod.
– Engage the positioning spring -3- with Hook -3438- .

– Engage the tension spring -1- from the wedge -2-.
– Insert the brake shoes between the wheel hub and the brake
support.
– Install the shoes in the brake cylinder plunger.
– Couple the parking brake cable to wthe
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– Install the lower positioningedspring
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ss spring ⇒ Item 2 (page 62) with the c
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– Install the brake drum.

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– Install the wheels. ility
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– Adjust the parking brake ⇒ page 68 .

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2. Rear wheel brake (drum brake) - repair 65

3 Parking brake - Assembly overview
1 - Parking brake lever knob

❑ Remove and install ⇒
Body - internal mount‐ agen
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2 - Compensation arch s
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3 - Adjusting nut
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5 - Rubber cauls
6 - Right guide tube
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7 - Left guide tube
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8 - Parking brake lever support

9 - Parking brake cables
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⇒ page 66
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10 - Parking brake control
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11 - Parking brake lever
3.1 Parking brake cable (drum brake) - re‐

move and install
3.1.1 Removal
– Remove the handle and the parking brake adjustment cover
⇒ Body - internal mountings; Rep. Gr. 68 ; Parking brake lever
handle - remove and install .
– Release the parking brake.

– Loosen nut -arrow- until the parking brake can be removed

outwards the compensation footboard.
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– Unscrew the nuts -1- and push the floor protection downwards
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until the guide tube -2- from the parking brake cable becomes
visible.
– Remove the rear wheel.
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– Remove the brake drum.
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– Release the parking brake cable.
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– Pull the parking brake cable towards the -arrow- outwards the
guide tube -1-.
3.1.2 Installation
– Insert the parking brake cable into the guide tube.
– Couple the parking brake cable to the brake lever.
– Install the brake drum.
3. Parking brake - Assembly overview 67

– Attach the parking brake cable into the rear axle body support
-arrow A-.
Note
The parking brake cable retainer ring shall be in the middle of the
clip.
– Fit the parking brake cable into its respective supports

-arrows-.
– Insert the parking brake cable in the compensation arc.
– Previously tighten the parking brake cable with the nut

-arrow-.
– Adjust the parking brake ⇒ page 68 .
– Fasten the floor protection.
– Install the knob and the parking brake adjustment cover ⇒
Body - internal mountings; Rep. Gr. 68 ; Parking brake lever
3.2 Parking brake - adjust

• The brake must be operational and bled.
– Remove the handle and the parking brake adjustment cover
⇒ Body - internal mountings; Rep. Gr. 68 ; Parking brake lever
– Remove the wheels. lkswage es n
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– Reposition the brake ⇒ page 63 rised ran
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– Fully lift the brake wedges. ss a ac
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– Loosen and remove the parking brake cables from the lever
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– Press the brake pedal with a force of approximately 300 N.

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– Assemble the cables and tighten the nut -A- until it is no longer
possible to turn the wheels manually.
– Loosen nut -A- until the wheel turns freely. Slight rubbing is AG. Volkswagen
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– Release the parking brake and check that the wheels turn
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Note
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♦ A slight rubbing of the pads against the drum is allowed.
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3. Parking brake - Assembly overview 69

4 Brake pedal - Assembly overview
WARNING
The brake pedal stroke shall not be shortened with additional

floor linings.
Before assembling, all bearing points should be lubricated with

Grease -G 000 602- .
1 - Support
2 - Hexagon screw
3 - Hexagon nut
❑ Self-locking
❑ 28 Nm
4 - Brake light switch -F-
❑ Before assembling the
Brake light switch -F- ,
the brake pedal must be
fitted with the servo
brake actuating rod.
❑ Adjust the Brake light
switch -F- ⇒ page 74
5 - Accelerator pedal
6 - Brake pedal
⇒ page 72
7 - Bearing bushing
8 - Cover AG. Volkswagen AG d
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9 - Support pin ed b ara
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10 - Hexagon nut aut ra
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❑ Self-locking
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11 - Servo brake
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13 - Module support
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14 - Crash bar anchor

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15 - Hexagon screw
❑ 10 Nm
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4.1 Pedal set - remove and install

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Rep. Gr.46 - Brakes - Mechanical system Prote AG.
♦ Unlock tool -T10006A-
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4.1.1 Removal
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– Remove the instrument panel. ⇒ Body - internal mountings;
Rep. Gr. 70 ; Instrument panel - remove and install .
rrectness of i
– Remove heating baffle ⇒ Heating, air conditioning; Rep. Gr.
l purpos
80 ; Left footwell air duct - remove and install .

– Loosen the screws -1-.
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– Remove cover -2-.
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– Disengage the accelerator cable.
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– Then, press and hold the brake pedal towards the servo brake.
1- Brake pedal
2- Brake cylinder operating rod
3- Fastening shoulders
– Position Unlock tool -T10006A- and pull it towards the driver's
seat, at the same time hold the brake pedal (at this time, the
pedal cannot move backwards). With this, the fastening
shoulders -3- of the drive rod's spherical head housing are
pressed away from the actuating rod -2-.
4. Brake pedal - Assembly overview 71

– Remove the hexagon nuts -arrows-.
Note
The upper hexagonal nut for fastening the pedal set is not visible
in the figure. It is found on the rear wall, behind the impact strut
⇒ Item 3 (page 70)
– Remove the pedal cluster. agen

AG. Volkswagen AG d
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4.1.2 Installation
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following:
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– Hold the operating rod ball head in front of the housing and
l purpos
press the brake pedal towards the servo brake until the ball
head coupling is heard.
nform
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– Hexagon nut tightening torque: 28 Nm.

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– Adjust the Brake light switch -F- ⇒ page 74 .
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4.2 Brake pedal - remove and install Prote AG.

♦ Unlock tool -T10006A-
4.2.1 Removal


the connector under the instrument panel. n AG. Volkswagen A ge G do
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– Remove the Brake light switch -F- , turning itb45°
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1- Brake pedal
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– Position Unlock tool -T10006A- and pull towards the driver's
rrectness of i
seat. At the same time, hold the brake pedal (at this time, the
pedal cannot move backwards). With this, the fastening
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shoulders -3- of the drive rod's spherical head housing are

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– Loosen the fastening nut -1- and remove the hexagonal head p by
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screw -arrow-.
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– Remove the brake pedal -2-.
4.2.2 Installation
following:

– The tightening torque for the hexagonal nut -1- 25 Nm.

4.3 Brake pedal switch -F47- - remove and

install
4.3.1 Removal
– Disconnect the brake light connector.
– Remove the Brake pedal switch -F47- , turning it 45° to the left.
AG. Volkswagen AG d
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– Before installing, tapply
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The installation of the Brake pedal switch -F47- must be carried

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out with the brake pedal in its resting position. The brake pedal
hole
spec
may not be activated before the end of the procedure.

es, in part or in w
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74
cop Vo
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Rep. Gr.46 - Brakes - Mechanical system Prote
cted AG.
agen
– Introduce the Brake pedal switch -F47- in its respective hous‐

ing, pressing it lightly against Athe
G. Vbrake
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fasten it by turning itVoby 45°
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– Engage the connector
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– Press thessbrake
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of vehicle) lights.
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47 – Brakes - Hydraulic system, servo brake

1 Front brake caliper (FS II) - repair
♦ In case of repairs, install the full repair set.
♦ New brake calipers are supplied with brake fluid and previ‐
ously bled.
♦ Apply a light coat of Grease -G 052 150 A2- on the brake cyl‐
inder, plungers and sealing ring. ⇒ Refer to Chemicals Man‐
ual .
1 - Brake caliper housing

2 - Protection cover
❑ Fit the bleed valve
3 - Bleeder valve
❑ 10 Nm
❑ Before installing, apply
a thin layer of Grease -G
052 150 A2- on the
thread
4 - Upper spacer sleeve
❑ Assemble with Grease -
AG. Volkswagen AG d
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8 - Lower bushing
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G 052 150 A2-
9 - Lower spacer sleeve
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G 052 150 A2-

10 - Seal ring
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❑ Remove it with a ?as‐

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❑ Prior to installation, apply a slight coat ?of Grease -G 052 150 A2-
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76 Rep. Gr.47 - Brakes - Hydraulic system, servo brake

1.1 Plunger for front brake caliper - remove

and install
♦ ?assembly Wedge -3409-
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1.1.1 Removal
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– Remove the brake caliper housing plungers with compressed

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Note
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Place a wooden plate in the area so that the plunger is not dam‐
aged.
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– Remove the sealing ring with the ?assembly Wedge -3409- .

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While removing, make sure that the cylinder surface is not dam‐
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1. Front brake caliper (FS II) - repair 77

1.1.2 Installation
Note
Clean the plunger surfaces and seal ring with alcohol only and
dry them immediately afterwards.
– Apply a light coat of Grease -G 052 150 A2- to the plunger and
sealing ring.
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– Install the internal lip in the cylinder groove using the ?assem‐
bly Wedge -3409- .
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Hold the plunger in front of the brake caliper housing.

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– Press the plunger with the Plunger resetting device -T10145- Prote
cted AG.
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inward the brake caliper case.
The external protection cover lip fits into the plunger groove.

2 Front brake caliper, brake caliper (FS

II) - repair
♦ In case of repairs, install the full repair set.
♦ New brake calipers are supplied with brake fluid and previ‐
ously bled.
♦ Apply a light coat of Grease -G 052 150 A2- on the brake cyl‐
inder, plungers and sealing ring. ⇒ Refer to Chemicals Manual
❑ Fit the bleed valve
2 - Bleeder valve
❑ 10 Nm
❑ Before installing, apply
a thin layer of Grease -G
052 150 A2- on the
thread
3 - Support sleeve
4 - Guide pin
❑ 30 Nm AG. Volkswagen AG d
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5 - Cover cap d by
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❑ Assemble to support hor eo
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6 - Brake caliper housing

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7 - Seal ring
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⇒ page 79
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8 - Plunger
spec
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⇒ page 79
❑ Prior to installation, ap‐
ply a slight coat ?of
rrectness of i
Grease -G 052 150 A2-
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9 - Seal ring
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⇒ page 79
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2.1 Front brake caliper plunger - remove

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Special tools and workshop equipment required op Vo
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Prote AG.
2. Front brake caliper, brake caliper (FS II) - repair 79

♦ ?assembly Wedge -3409-
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♦ Plunger resetting device -T10145- tho tee
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2.1.1 Removal
– Remove the brake caliper housing plungers with compressed
nform
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Note
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Place a wooden plate in the area so that the plunger is not dam‐
rp
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Prote AG.
– Remove the sealing ring with the ?assembly Wedge -3409- .
Note
While removing, make sure that the cylinder surface is not dam‐
aged.

2.1.2 Installation
Note
Clean the plunger surfaces

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AG. seal ring withdoalcohol
Volkswagen AG
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– Install the internal lip in the cylinder groove using the ?assem‐ atio
m
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Hold the plunger in front of the brake caliper housing.

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Prote AG.
– Press the plunger with the Plunger resetting device -T10145-

inward the brake caliper case.
The external protection cover lip fits into the plunger groove.
2. Front brake caliper, brake caliper (FS II) - repair 81

3 Braking power adjustment - Assem‐

bly overview
Only for vehicles without ABS.
1 - Braking power adjustment

❑ Adjust ⇒ page 82
❑ Check ⇒ page 83
2 - Support
3 - Hexagon nut
❑ Self-locking
❑ 17 Nm
❑ ?Right rear wheel brake
cylinder
❑ 14 Nm
AG. Volkswagen AG d
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❑ ?Left rear wheel brake ed by gu
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❑ 14 Nm
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❑ Brake master-cylinder/
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❑ 14 Nm
8 - Retaining support
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❑ 20 Nm
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10 - Hexagon screw
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11 - Nut
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13 - Brake hose
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14 - Axle beam
Prote AG.
15 - Hexagon screw
❑ 16 Nm
3.1 Brake pressure regulator - adjust

Perform the adjustments according to the following conditions:
• Excessively high testing pressure on the rear axle:
– Relieve the adjustment spring.

olkswagen AG
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• Excessively low testing pressure on the rear
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– Tension the adjustment spring. rise nte
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The regulator spring shall be never relieved or tensioned with the
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activated brake pedal.
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Proceed according to the following sequence:
hole
spec
es, in part or in w
– Check the brake pressure regulator ⇒ page 83 .
t to the co
– Adjust the spring.
– Check the values again ⇒ page 83 .
rrectness of i
– If necessary, re-make the adjustment.
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3.2 Brake pressure regulator - check
nform
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♦ Control equipment for brake systems -V.A.G 1310 A-
on
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Check conditions:
his
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• Fuel tank is completely filled

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• Driver's weight approximately 75 Kg

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• Windshield washer system container is completely filled
AG.
– Lift the vehicle on a board-type elevator or use a trench.
3. Braking power adjustment - Assembly overview 83

– Remove the cylinder bleeding screws and install the adapters

for the Control equipment for brake systems -V.A.G 1310 A-
diagonally, the front left wheel cylinder with the right rear wheel
cylinder, or the right front wheel. Vcylinder with the left rear wheel
AG olkswagen AG d
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– Bleed the equipment
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Do not allow lack of brake fluid in the reservoir.
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– Apply the brake pedal until the front wheel pressure gauge
h re
indicates 70 bar and compare it to the values obtained on the
hole
spec
rear wheel according to the specified values.
es, in part or in w
t to the co
Version Bar
Drum brake in the Front axle 70 100
rrectness of i
rear axle Rear axle 35,6 ... 41,6 48,5 ... 54,5
l purpos
– Repeat the check for 100 bar.

– When the values do not correspond to those specified and the
nf
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system does not present any leakages or other abnormalities,
rm
m
adjust the pressure regulator again. If the values remain dif‐ atio
om
ferent from the specification values, replace the regulator.

n in
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– Remove Control equipment for brake systems -V.A.G 1310 A-

t
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and bleed the brake system ⇒ page 85 .

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WARNING
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♦ Never reuse drained fluid.
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Prote AG.

SpaceFox, Space Cross, ageSuran,
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lkswagen AG
doesSportvan 2006 ➤
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Brake systems - oEdition
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05.2011
ed ran
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4 Brake system - bleed
ac
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WARNING
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♦ Use only new brake fluid, in accordance with standard US
wit
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FMVSS 116 DOT 4.
hole
spec
♦ The original VW/Audi brake fluid corresponds to this spec‐
es, in part or in w
ification.
t to the co
♦ The brake fluid is toxic. Due to its acidic properties it
should not come into contact with painted surfaces.
rrectness of i
♦ Brake fluid is hygroscopic, i.e. it absorbs environmental
l purpos
humidity and shall always be stored in air tight containers.

♦ Wash brake fluid leakages with plenty of water.
nform
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com
tio
4.1 Brake system - Bleed with brake replen‐
n in
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ishment and bleed equipment
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♦ Brake filling and bleeding equipment -VAS 5234- t. Cop py
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or
♦ Brake filling and bleeding equipment -V.A.G 1869-
♦ Accessory set for bleeder -V.A.G 1869/4-
Note
On vehicles equipped with ABS/EDS/ASR, the system shall be

bled when the brake fluid reservoir is completely empty (e.g.,
brake system leakages) ⇒ page 86
4. Brake system - bleed 85

Brake systems - Edition 05.2011 gen AG
. Volkswagen AG
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– Connect the Brake filling and bleedingiseequipment
d b -VAS 5234- ara
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or -V.A.G 1869- . tho
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c
– Open the bleed valves in the following sequence and bleed ss
ce
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the brake cylinder/caliper.
nl
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Bleeding sequence for Bosch 5.7, 8.0 and 8.2
erm
ab
ility
1 - Right rear brake cylinder/caliper ot p
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2 - Left rear brake cylinder/caliper
hole
spec
3 - Right front brake caliper
es, in part or in w
t to the co
4 - Left front brake caliper
– Keep the bleed valves open with the hose connected until the
rrectness of i
fluid comes out without any air bubbles.
l purpos
After bleeding, perform a test drive carrying out at least one ABS
regulated braking!
nf
ercia
4.2 Brake system - Bleed without brake re‐
orm
m
atio
plenishment and bleed equipment
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In order to do the bleeding without using the Brake filling and
thi
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sd
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bleeding equipment -V.A.G 1869- or -V.A.G 1869- it is required

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the aid of a second person.
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– Open the bleeding valve.
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– Apply the brake pedal until its end stop. Prote
cted AG.
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– Close the valve while pressing the brake pedal.

– Slowly release the brake pedal.
This bleed procedure shall be performed 5 times per brake cyl‐
inder/caliper.
– Open the bleed valves in the following sequence:
1 - Right rear brake cylinder/caliper
2 - Left rear brake cylinder/caliper
3 - Right front brake caliper
4 - Left front brake caliper
regulated braking!
4.3 Brake system with ABS/EDS/ASR -

Bleed when the reservoir is empty
♦ Brake filling and bleeding equipment -VAS 5234-

or
♦ Brake filling and bleeding equipment -V.A.G 1869-
AG. Volkswagen AG d
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♦ Accessory set for bleeder -V.A.G 1869/4-
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erm
– Connect the Brake filling and bleeding equipment -VAS 5234-
ab
ility
or -V.A.G 1869- .
ot p
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– Open the bleed valves in the following sequence and bleed
h re
hole
the brake cylinder/caliper.
spec
es, in part or in w
1 - Simultaneously bleed the left and right front brake calipers
t to the co
2 - Simultaneously bleed the left and right brake calipers/cylinders
rrectness of i
– Keep the bleed valves open with the hose connected until the
fluid comes out without any air bubbles.
l purpos
Then, the hydraulic unit must be bled once again, by means of

the Diagnosis, Measurement and Information System -VAS
nform
ercia
5051A/52- in the function “Basic adjustment”.

m
at
om
ion
regulated braking!
c
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or
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ate
do
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4. Brake system - bleed 87

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Brake systems - aEdition
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5 auBrake booster/brake master cylinder
tho or
ac
ss
- Assembly overview
ce
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The brake cylinder and the servo brake can be independently re‐
y li
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ab
placed.
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1 - Servo brake
ole,
spec
❑ On gasoline engines,
the required vacuum is
t to the co
taken from the intake
manifold
rrectne
❑ On ??diesel engines,
there is a vacuum pump
for vacuum transforma‐
ss
tion
o
cial p
f in
❑ Check the operation:
form
mer
atio
– Fully press the brake
om
pedal several times with
n
c
i
or
n
the engine turned off
thi
te
sd
(this eliminates any re‐
iva
o
r
maining vacuum inside

p
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the servo-brake).
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– Hold the brake pedal
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braking position and
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turn the engine on. A
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fully operational servo

brake may be sensed
when the operator's feet
is on the pedal (active
multiplication).
– In case of faults, com‐

pletely replace the servo
brake.
❑ Verify the check valve
(in the vacuum hose)
⇒ page 91
⇒ page 94
2 - Brake oil level warning con‐
tact -F34-
3 - Cover
4 - Brake fluid reservoir
5 - Sealing plug
❑ Moist with brake fluid and press into the brake master cylinder
6 - Hexagon nut
❑ Self-locking
❑ 20 Nm
7 - Brake cylinder
❑ Cannot be repaired. In case of fault, replace it completely
8 - Retaining pin for the brake fluid reservoir
❑ Insert through the brake master cylinder

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9 - Seal ring wage
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❑ Replace whenever the master
ed cylinder is removed
by ara
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10 - Sealing plug au
th ra
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❑ Connection for vacuum hose
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11 - Vacuum hose
itte
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12 - Caul
ility
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❑ Watch for proper seating, as there may occur aspiration noises
wit
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hole
13 - Hexagon nut
spec
es, in part or in w
❑ Self-locking
t to the co
❑ 28 Nm
14 - Sealing
rrectness of i
❑ To servo-brake
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nf
5.1 Servo brake vacuum pump (diesel vehi‐
ercia
orm
cles) - remove and install
m
atio
om
n in
or c
thi
te
sd
a
5.1.1 Vacuum pump for 4-cylinders diesel en‐

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gines and with distribution injector pump
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Removal t. C rig
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– Loosen the fastening clamp -arrow A- from the vacuum hose,
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disconnect the hose.
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– Loosen the screw -arrow B- on the head flange.

– Remove the vacuum pump.
5. Brake booster/brake master cylinder - Assembly overview 89

Seal the vacuum pump

2 - Cover
3 - 0-Ring
- replace
4 - Vacuum pump
5 - 0-Ring
- replace
6 - Hexagonal head screw, 20 Nm n AG. Volkswagen AG do
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7 - Support byV
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♦ It is not possible to repair the vacuum uth pump.
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or
a ac
♦ To seal, replace the two O-Rings pos. 3 and 5. ss
ce
le
un
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Installation
an
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ab
When installing the vacuum pump, ensure the proper fitting to the
ility
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driving gear.
wit
is n
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ole,
– Fasten the screw -arrow B- to the flange and install the vacuum
spec
hose with the clamp -arrow A-.
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
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va
5.1.2 Vacuum pump for 3-cylinder diesel en‐

i
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pr
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Tandem pump -1- (vacuum pump and fuel pump).
t. rig
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Vacuum hose -2- to servo brake with check valve.
c by lksw
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Fuel tube sets -3- and -4-
– Remove and install⇒ Rep. Gr. 20 ; Fuel supply system com‐
ponents - remove and install .
5.1.3 Vacuum pump for 4-cylinder diesel en‐

gines with injector pump unit
Tandem pump -1- (vacuum pump and fuel pump).
Vacuum hose -2- to servo brake with check valve.
Fuel tube sets -3- and -4-.
– Remove and install⇒ Rep. Gr. 20 ; Fuel supply system com‐
ponents - remove and install; .

5.2 Check valve - check

– Inspect the check valve
-A-.
Air must pass through the valve in the arrow direction.
The valve must remain closed in the opposite direction.
Pay attention to the correct assembly position.
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es, in part or in w
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rrectness of i
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91
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5. Brake booster/brake master cylinder - Assembly overview
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6 Brake cylinder - remove and install
Special tools and workshop

equipment required
♦ Clamps (diam. 25 mm)
-3094-
♦ Torque wrench - 5 to 50Nm
(socket 1/2") -VAG 1331-
♦ Brake pedal compression n AG. Volkswagen AG do
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device -VAG 1869/2- byV
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♦ Brake filling and bleeding utho tee
or
equipment -V.A.G 1869- ss
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♦ Brake replenishment and

nl
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du
an
bleed equipment -VAS
itte
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5234-
erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
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6.1 Removal
Note
♦ Check whether the vehicle has a coded radio. If so, request

the anti-theft code before disconnecting the battery earth
strap.
♦ When the battery is reconnected, check the operation of the
– Place an adequate number of lint-free cloths in the area

around the water reservoir, engine and transmission.

– Draw as much brake fluid as possible from the reservoir by

using Brake replenishment and bleed equipment -VAS 5234-
or -V.A.G 1869/4- .
– Close the clutch cylinder return hose with the Clamp (diam. 25
mm) -3094- .
– Disconnect the clutch cylinder return hose.
– Disconnect the connector of the Brake oil level warning con‐
tact -F34- .
– Release the brake lines in the brake master cylinder and close
them with the plugs of Repair set of plugs
wa-1H0
gen AG698 311 A-
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– Release the brake cylinder nuts.ed by ara
nte
is
or eo
– Carefully remove the servo abrake
ut
h
cylinder. ra
ss c
6.2 Installation
ce
e
nl
pt
du
an
itte
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erm
ab
following:
ility
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– When joining the brake cylinder to the servo brake, ensure the
h re
operating rod is properly seated in the brake cylinder.
hole
spec
es, in part or in w
– Tighten the nuts on the master cylinder with 20 Nm.
t to the co
– Tightening torque for the brake pipes 14 Nm.
– Connect the master cylinder piping:
rrectness of i
Vehicles without ABS
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1- Right front brake tube
nf
ercia
2- Left front brake tube
orm
m
atio
3- Rear break tube for breaking power adjuster ⇒ page 82
om
n in
or c
4- Rear break tube for breaking power adjuster ⇒ page 82 thi

te
sd
iva
Vehicles with ABS 5.7 ⇒ page 13

o
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Vehicles with ABS 8.0 ⇒ page 23

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Vehicles with ABS 8.2 ⇒ page 23 t. C rig
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6. Brake cylinder - remove and install 93

7 Servo brake - remove and install
Special tools and workshop

equipment required AG. Volkswagen AG d
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♦ Clamps (diam. 25 mm) d by ara
ise nte
-3094- hor eo
aut ra
c
♦ Torque wrench - 5 to 50Nm ss
ce
(socket 1/2") -VAG 1331- le
un
pt
an
d
itte
y li
♦ Break bleeding device -
erm
ab
V.A.G 1869-
ility
ot p
wit
♦ Brake replenishment and
is n
h re
bleed equipment -VAS
ole,
spec
5234-
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
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t. rig
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pyri by
Vo
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by c lksw
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♦ Unlock tool -T10006 A-
7.1 Removal

Note
wage
♦ Check whether the vehicle yV
has
olks a coded radio. If so, request
es n
ot g
the anti-theft code before
ir se
d disconnecting the battery earth uara
b
nte
strap. tho eo
u ra
sa
When the battery is reconnected, check the operation of the
c
♦ s
ce
e

nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
– Place an adequate number of lint-free cloths in the area
, is n
h re
around the water reservoir, engine and transmission.
hole
spec
– Draw as much brake fluid as possible from the reservoir by
es, in part or in w
t to the co
using Brake replenishment and bleed equipment -VAS 5234-
or -V.A.G 1869/4- .
– Close the clutch cylinder return hose with the Clamp (diam. 25
rrectness of i
mm) -3094- .
l purpos
– Disconnect the clutch cylinder return hose.

– Disconnect the connector of the Brake oil level warning con‐
nf
ercia
o
tact -F34- .
rm
m
atio
m
– Release the brake lines in the brake master cylinder and close
o
n in
c
them with the plugs of Repair set of plugs -1H0 698 311 A- .
or
thi
te
sd
a
– Disconnect the vacuum hose from the servo brake.

iv
o
r
rp
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– Remove the instrument panel. ⇒ Body - internal mountings; m

f
en
ng
t.
yi
Rep. Gr. 70 ; Instrument panel - remove and install .
Co
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t. rig
gh
ht
pyri by
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cted agen
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the connector under the instrument panel.
– Remove the Brake light switch -F- , turning it 45° to the left.
7. Servo brake - remove and install 95

– Then, press and hold the brake pedal towards the servo brake.
1- Brake pedal
AG. Volkswagen AG d
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– Position Unlock tool -T10006A-
olks
w
and pull it towards the
es n
odriver's
tg
yV
seat, at the same time ed hold the brake pedal (at this time,uathe
b ran
is
pedal cannot movetho backwards). With this, the fastening
r tee
or
shoulders -3-ssof the drive rod's spherical head housing are
au ac
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectne
– Remove the hexagon nuts -arrows-.
– Uncouple the servo brake with the brake cylinder forward and
ss
remove.
o
cial p
f inform
mer
atio
om
n
c
i
or
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te
sd
iva
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pr
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en
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rig ht
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7.2 Installation
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following:
– Hexagon nut tightening torque: 28 Nm.
– Prior to the installation of the switch, completely remove the
rod.

– Insert the switch through the assembly opening, press it

against the pedal and fix it by turning it 45° to the right.
– Keep the brake pedal at resting position.
– Engage the connector Brake light switch -F- .
– Check the brake light operation.
After adjusting, check whether the Brake light switch -F- is at the
final stop (loose position).
05.11
AG. Volkswagen AG d
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7. Servo brake - remove and install 97

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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2015 Volkswagen AG, Wolfsburg D3E802FFE59

45 - Anti-lock Braking System (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

11 ESP system components - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

11.2 Steering angle sensor G85 - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

3.2 Parking brake - adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

47 - Brakes - Hydraulic system, servo brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

6 Brake cylinder - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

7 Servo brake - remove and install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

1.1 Brake PR number correspondence

1.1.1 Front wheel brake

PR number Front wheel brake

1LM / 1LA / 1ZN FS II (13”)

1LG / 1ZF / 1ZR/1LR FS III (14”)

1.1.2 Rear wheel brake (drum brake)

PR number Rear wheel brake

1KM TB 200 X 40 CR 19mm

1.2 Brake technical data

-4- Brake caliper FS III (15”)

-2- Brake pad, mm 5

1.2.3 Rear wheel brake (drum brake, with

2 Rep. Gr.00 - Technical data

45 – Anti-lock Braking SystemVol(ABS)

♦ During the test drive, ensure at least one brake adjustment is

performed (a slight pulsing on the brake pedal shall be felt).

must be maintained, and under no circumstances, materials

♦ The components removed must be placed on a clean surface

1. Information on repair works on the ABS 3

2 Connect the Diagnosis, Measure‐

ment must always be fastened to the rear seat of the

♦ During a test drive, only one person should operate this

– Connect the diagnostic cable connector Diagnostic cable -

VAS 5051/1- or the Diagnostic cable -VAS 5051/3- to the

– Connect the Diagnosis, Measurement and Information Sys‐

4 Rep. Gr.45 - Anti-lock Braking System (ABS)

3 General information on the Bosch 5.7

3. General information on the Bosch 5.7 antilock braking system (ABS) 5

4 General information on the Bosch 8.0

6 Rep. Gr.45 - Anti-lock Braking System (ABS)

5 General information on the Bosch 8.2

1 - Hydraulic system unit and

Bosch 8.2 (ABS) :

5. General information on the Bosch 8.2 antilock braking system (ABS) 7

6 Electrical/electronic components and

6.1 ABS Bosch 5.7

1 - ABS hydraulic unit -N55-

the instrument panel

6 - Brake system control light -

the instrument panel

❑ Installation location: footwell lining on the driver's side

❑ Installation location: if there is any, on the instrument panel

6.2 ABS Bosch 8.0 (ABS/ESP)

1 - ABS control unit -J104-

2 - ABS hydraulic unit -N55-

The hydraulic unit comprises

the following components:

take and exhaust

❑ A ABS reflux pump -

V39- and the valves

may not be separated.

❑ Remove and install