Brake systems

Chapter overview

• Technical data
  1
• 1 Brake allocation via PR No
  1
• 1.1 Front brakes, Golf
  1
• 1.2 Front brakes, Eos
  2
• 1.3 Rear brakes, front-wheel drive Golf
  2
• 1.4 Rear brakes, four-wheel drive Golf
  3
• 1.5 Rear brakes, Eos
  3
• 2 Technical data for brakes
  4
• 2.1 Brake master cylinder and brake servo
  4
• 2.2 Front brakes
  4
• 2.3 Rear brakes (disc brakes)
  6
• 3 Brake test
  9
• 3.1 General
  9
• 3.2 Test for vehicles with front-wheel drive
  9
• 3.3 Test for vehicles with four-wheel drive via a Haldex coupling
  9
• Anti-lock brake system
  11
• 1 General notes on anti-lock brake system
  11
• 2 Notes for repair work on anti-lock brake system
  12
• 3 Connecting VAS 5051 and selecting functions
  13
• 4 Electrical/electronic components and locations
  15
• 4.1 ABS Mark 70 (ABS/TCS)
  15
• 4.2 ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 22/2008
  17
• 4.3 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 22/2008
  19
• 5 Fault display via warning lamps
  22
• 6 Assembly overview - hydraulic unit, brake servo/brake master cylinder
  24
• 6.1 ABS Mark 70 (ABS/TCS)
  24
• 6.2 ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 22/2008
  30
• 6.3 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 22/2008
  38
• 7 Removing and installing parts of ABS system on front and rear axle
  46
• 7.1 Removing and installing parts of ABS system on front axle
  46
• 8 Removing and installing parts of ESP system
  50
• 8.1 Removing and installing ESP sensor unit G419
  50
• 8.2 Removing and installing steering angle sender G85
  51
• 8.3 Removing and installing brake servo vacuum sender G483
  51
• Brakes - mechanism
  53
• 1 Repairing front brakes
  53
• 1.1 Repairing front brakes, FS III brake caliper
  53
• 1.2 Removing and installing brake pads/linings
  54
• 1.3 Removing and installing brake caliper
  57
• 1.4 Repairing front brakes, FN 3 brake caliper
  59
• 1.5 Removing and installing brake pads/linings
  62
• 1.6 Removing and installing brake caliper
  65
• 1.7 Repairing front brake, FNR-G brake caliper
  67
• 1.8 Removing and installing brake pads/linings
  68
• 1.9 Removing and installing brake caliper
  71
• 2 Repairing rear brakes
  74
• 2.1 Repairing rear brake CI 38
  74
• 2.2 Removing and installing brake pads/linings
  75
• 2.3 Removing and installing brake caliper
  77
• 2.4 Repairing rear brake CII 38
  79
• 2.5 Removing and installing brake pads/linings
  81
• 2.6 Removing and installing brake caliper
  83
• 2.7 Repairing rear brake CII 41
  85
• 2.8 Removing and installing brake pads/linings
  87
• 2.9 Removing and installing brake caliper
  90
• 2.10 Assembly overview - Bosch rear wheel brake
  91
• 2.11 Removing and installing brake pads, Bosch
  93
• 2.12 Removing and installing brake caliper, Bosch
  95
• 2.13 Adjusting handbrake
  97
• 3 Assembly overview - handbrake lever
  99
• 3.1 Removing and installing handbrake cable up to model year 2007
  99
• 3.2 Removing and installing handbrake cable from model year 2008
  102
• 4 Assembly overview - brake pedal
  105
• 4.1 Separating brake pedal from brake servo
  105
• 4.2 Removing and installing brake light switch F from week 45 of 2005
  106
• Brakes - hydraulics
  109
• 1 Repairing front brake caliper
  109
• 1.1 Assembly overview - brake caliper FS III
  109
• 1.2 Removing and installing piston for brake caliper FS III
  109
• 1.3 Assembly overview - brake caliper FN 3
  111
• 1.4 Removing and installing piston for brake caliper FN 3
  112
• 1.5 Assembly overview - brake caliper FNR-G
  115
• 1.6 Removing and installing piston for FNR-G brake caliper
  116
• 2 Repairing rear brake caliper
  119
• 2.1 Assembly overview - brake calipers CI 38 and CII 38
  119
• 2.2 Assembly overview - brake caliper CII 41
  120
• 2.3 Removing and installing brake caliper piston
  121
• 2.4 Assembly overview - Bosch brake caliper
  123
• 2.5 Removing and installing brake caliper piston, Bosch
  124
• 2.6 Pre-bleeding brake caliper
  126
• 3 Pressurised leak test
  127
• 3.1 Test prerequisites:
  127
• 4 Bleeding brake system
  128
• 4.1 Bleeding brake system using brake filling and bleeding equipment VAS 5234 or V.A.G 1869
  128
• 4.2 Changing brake fluid
  130
• 5 Brake servo and brake master cylinder
  131
• 5.1 Assembly overview: brake servo/brake master cylinder (left-hand drive vehicle)
  131
• 5.3 Overview - vacuum pump for brake servo (diesel vehicles)
  134
• 5.4 Checking brake servo vacuum system
  135
• 5.5 Checking non-return valve
  139
• 5.6 Removing and installing brake servo pressure sensor G294
  139
• 5.7 Vacuum pump for brakes V192
  139
• 5.8 Removing and installing brake light switch F as of week 45/05
  140
• 6 Removing and installing brake master cylinder
  141
• 6.1 Removing
  141
• 6.2 Installing
  142
• 7 Removing and installing brake servo
  143
• 7.1 Removing
  143
• 7.2 Installing
  145
• 8 Brake lines
  146
• 8.1 Separating point on underbody
  146
• 8.2 Repairing brake lines
  146