Brake systems

Chapter overview

• Technical data
  1
• 1 Brake allocation via PR number
  1
• 1.1 Front brakes, Jetta
  1
• 1.2 Front brakes, Jetta, North America
  1
• 1.3 Front brakes, Jetta, Japan
  2
• 1.4 Front brakes, Bora, Mexico
  2
• 1.5 Front brakes, Golf Variant model year 2008
  2
• 1.6 Front brakes, Golf Variant from model year 2009
  2
• 1.7 Front brakes, Jetta SportWagen as of model year 2008 (USA)
  3
• 1.8 Rear brakes, Jetta up to week 50/2009
  3
• 1.9 Rear brakes, Jetta as of week 50/2009
  3
• 1.10 Rear brakes, Jetta, North America, up to week 50/2009
  3
• 1.11 Rear brakes, Jetta, North America, as of week 50/2009
  4
• 1.12 Rear brakes, Bora, Mexico, up to week 50/2009
  4
• 1.13 Rear brakes, Bora, Mexico, as of week 50/2009
  4
• 1.14 Rear brakes, Jetta, Japan, up to week 50/2009
  4
• 1.15 Rear brakes, Jetta, Japan, as of week 50/2009
  5
• 1.16 Rear brakes, Golf Variant from model year 2008
  5
• 1.17 Rear brakes, Golf Variant from model year 2009
  5
• 1.18 Rear brakes, Jetta SportWagen as of model year 2009 (USA)
  5
• 2 Technical data for brakes
  7
• 2.1 Brake master cylinder and brake servo
  7
• 2.2 Front brake FS III
  7
• 2.3 Front brakes FN 3 (15”)
  8
• 2.4 Front brakes FN 3 (16”)
  8
• 2.5 Rear brakes C 38
  8
• 2.6 Rear brake CII 38
  9
• 2.7 Rear brake CII 41 (15”)
  9
• 2.8 Rear brake CII 41 (16”)
  9
• 2.9 Rear brakes, Bosch
  10
• 3 Brake test
  11
• 3.1 General information
  11
• 3.2 Test for vehicles with front-wheel drive
  11
• 3.3 Test for vehicles with four-wheel drive via a Haldex coupling
  11
• Anti-lock brake system
  12
• 1 General notes on anti-lock brake system
  12
• 2 Notes for repair work on anti-lock brake system
  13
• 3 Connecting VAS 5051 and selecting functions
  14
• 4 Electrical/electronic components and locations
  16
• 4.1 ABS Mark 70 (ABS/TCS)
  16
• 4.2 ABS Mark 60 (ABS/EDL/TCS/ESP) to week 27/08
  18
• 4.3 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 27/08
  20
• 5 Fault display via warning lamps
  22
• 5.1 ABS/TCS
  22
• 5.2 ABS/EDL/TCS/ESP
  24
• 6 ABS Mark 70 (ABS/TCS)
  27
• 6.3 Removing control unit and hydraulic unit
  30
• 6.4 Unbolting control unit from hydraulic unit
  33
• 6.5 Installing new control unit
  34
• 6.6 Installing control unit and hydraulic unit
  34
• 7 ABS Mark 60 (ABS/EDL/TCS/ESP) to week 27/08
  36
• 7.1 Connecting brake lines from brake master cylinder to hydraulic unit, left-hand drive vehicle
  38
• 7.3 Removing control unit and hydraulic unit
  39
• 7.4 Unscrewing control unit from hydraulic unit
  42
• 7.5 Installing new control unit
  44
• 7.6 Installing control unit and hydraulic unit
  44
• 8 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 27/08
  46
• 8.1 Connecting brake lines from brake master cylinder to hydraulic unit, left-hand drive vehicle
  47
• 8.3 Removing control unit and hydraulic unit
  49
• 8.4 Unscrewing control unit from hydraulic unit
  53
• 8.5 Installing new control unit
  54
• 8.6 Installing control unit and hydraulic unit
  54
• 9 Removing and installing parts of ABS system on front and rear axle
  56
• 9.1 Removing and installing parts of ABS system on front axle
  56
• 10 Removing and installing parts of ESP system
  60
• 10.1 Removing and installing ESP sensor unit G419
  60
• 10.2 Removing and installing steering angle sender G85
  61
• 10.3 Removing and installing brake servo vacuum sender G483
  61
• Brakes - mechanism
  63
• 1 Repairing front brakes, FS III brake caliper
  63
• 1.1 Removing and installing brake pads, brake caliper FS III
  64
• 1.2 Removing and installing brake caliper, FS III brake caliper
  67
• 2 Repairing front brakes, FN 3 brake caliper
  70
• 2.1 Removing and installing brake pads, brake caliper FN 3
  73
• 2.2 Removing and installing brake caliper, FN 3 brake caliper
  76
• 3 Repairing rear brake C 38
  78
• 3.1 Removing and installing brake pads for C 38 brake caliper
  79
• 3.2 Removing and installing brake caliper C 38
  81
• 4 Repairing rear brakes CII 38/CII 41 (front-wheel drive)
  84
• 4.1 Removing and installing brake pads for CII 38/CII 41 brake caliper
  85
• 4.2 Removing and installing brake caliper CII 38/CII 41
  88
• 5 Repairing rear brake CII 41 (four-wheel drive)
  91
• 5.1 Removing and installing brake pads/linings
  92
• 5.2 Removing and installing brake caliper
  95
• 6 Repairing rear brakes, Bosch
  97
• 6.1 Removing and installing brake pads/linings
  98
• 6.2 Removing and installing brake caliper
  101
• 7 Adjusting handbrake up to week 50/2009
  104
• 8 Adjusting handbrake as of week 50/2009
  105
• 9 Assembly overview - handbrake lever
  106
• 9.1 Removing and installing handbrake cable up to model year 2007
  106
• 9.2 Removing and installing handbrake cable from model year 2008
  109
• 10 Assembly overview - brake pedal
  112
• 10.1 Separating brake pedal from brake servo
  113
• 10.2 Clipping brake pedal to brake servo
  113
• 10.3 Brake light switch F to week 50/05 (left-hand drive vehicles)
  114
• 10.4 New version of brake light switch (left-hand drive vehicles)
  115
• 10.5 Brake light switch (right-hand drive vehicles)
  116
• Brakes - hydraulics
  117
• 1 Repairing front FS III brake caliper
  117
• 1.1 Removing and installing piston for brake caliper FS III
  117
• 2 Repairing front FN 3 brake caliper
  120
• 2.1 Removing and installing piston for brake caliper FN 3
  121
• 3 Repairing rear brake caliper
  124
• 3.1 Repairing brake caliper C 38/CII 38
  124
• 3.2 Repairing CII 41 brake caliper
  125
• 3.3 Removing brake caliper piston
  126
• 3.4 Installing brake caliper piston
  127
• 3.5 Pre-bleeding brake caliper
  128
• 4 Repairing Bosch rear brake calipers
  129
• 4.1 Removing and installing brake caliper piston
  130
• 4.2 Pre-bleeding brake caliper
  132
• 5 Pressurised leak test
  133
• 5.1 Prerequisites for testing:
  133
• 6 Bleeding brake system using brake charge and bleed equipment VAS 5234 or V.A.G 1869
  134
• 6.1 Pre-bleeding
  135
• 6.2 Bleeding (normal)
  135
• 6.3 Subsequent bleeding
  136
• 6.4 Changing brake fluid (every 2 years)
  136
• 7 Brake servo and brake master cylinder
  137
• 7.1 Assembly overview - brake servo/brake master cylinder (left-hand drive vehicle)
  137
• 7.2 Assembly overview - brake servo/brake master cylinder, RHD
  139
• 7.3 Overview - vacuum pump for brake servo (diesel vehicles)
  140
• 7.4 Checking non-return valve :
  141
• 7.5 Removing and installing brake servo pressure sensor G294
  141
• 7.6 Brake servo vacuum pump (5-cyl. petrol engine)
  142
• 7.7 Brake servo vacuum pump (4-cyl. petrol engine)
  142
• 7.8 Assembly overview - vacuum pump for brakes V192
  142
• 7.9 Removing and installing vacuum pump for brakes V192
  143
• 7.10 Removing and installing brake light switch F from week 50/05
  144
• 8 Removing and installing brake master cylinder
  146
• 9 Removing and installing brake servo
  149
• 9.1 Removing
  150
• 9.2 Installing
  152
• 10 Repairing brake lines
  154
• 10.1 Assembly overview - flanging tool
  156
• 10.2 Work instructions
  156