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  • Examplepage for repair manual Brake systems
  • Examplepage for repair manual 2 Brake systems
  • Examplepage for repair manual 3 Brake systems
  • Examplepage for repair manual Brake systems
  • Examplepage for repair manual 2 Brake systems
  • Examplepage for repair manual 3 Brake systems

Brake systems

For Polo Sedan / Polo

Original Volkswagen repair manual


13,85 €7% VAT incl.

Immediately available for download

Language: English

Digital PDF file

4.225 KB

162 Sites

Detailed technical data

Immediately readable

This repair manual contains: General notes for anti-lock brake system (ABS), Connecting VAS 5051 and selecting functions, Fault display via warning lamps, Assembly overview - hydraulic unit, brake servo/brake master cylinder, Removing and installing parts of ABS system on front and rear axle, Repairing rear brakes (drum brakes) and Pressure leak test. Show more
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Repair manual Polo Sedan / Polo Brake systems PDF download has the following content:

Chapter overview

  • Technical data
    1
  • 1 Brake allocation via PR No
    1
  • 1.1 Front brakes
    1
  • 1.2 Rear brakes
    2
  • 2 Technical data for brakes
    4
  • 2.1 Brake master cylinder and brake servo
    4
  • 2.2 Front brakes
    4
  • 2.3 Rear brakes
    5
  • 3 Brake test
    7
  • 3.1 General
    7
  • 3.2 Test for vehicles with front-wheel drive
    7
  • Anti-lock brake system
    8
  • 1 General notes for anti-lock brake system (ABS)
    8
  • 1.1 ABS Mark 60
    8
  • 1.2 ABS Bosch 5.7
    9
  • 1.3 Bosch 8.0 as of model year 2005
    10
  • 2 Notes for repair work on anti-locking brake system
    12
  • 3 Connecting VAS 5051 and selecting functions
    13
  • 4 Electrical/electronic components and fitting locations
    15
  • 4.1 ABS Mark 60 (ABS, ABS/EDL/TCS)
    15
  • 4.2 ABS Bosch 5.7 (ABS/EDL/TCS/ESP)
    16
  • 4.3 ABS Mark 8.0 (ABS, ABS/TCS)
    18
  • 4.4 ABS Bosch 8.0 (ABS/EDL/TCS/ESP)
    19
  • 5 Fault display via warning lamps
    21
  • 6 Assembly overview - hydraulic unit, brake servo/brake master cylinder
    23
  • 6.1 ABS Mark 60
    23
  • 6.2 ABS/EDL/TCS/ESP Bosch 5.7
    33
  • 6.3 Bosch 8.0 ABS, ABS/TCS
    42
  • 6.4 Bosch 8.0 ABS/EDL/TCS/ESP
    50
  • 7 Removing and installing parts of ABS system on front and rear axle
    58
  • 7.1 Removing and installing parts of ABS system on front axle
    58
  • 8 Removing and installing parts of ESP system
    72
  • 8.2 Removing and installing steering angle sender G85
    73
  • Brakes - mechanism
    74
  • 1 Repairing front brakes
    74
  • 1.1 Repairing front brakes, brake caliper FS II
    74
  • 1.2 Removing and installing brake pads, brake caliper FS II
    75
  • 1.3 Removing and installing brake caliper FS II
    77
  • 1.4 Repairing front brakes, brake caliper FS III
    79
  • 1.5 Removing and installing brake pads, brake caliper FS III
    81
  • 1.6 Removing and installing brake caliper FS III
    83
  • 1.7 Repairing front brakes, brake caliper C 54-II
    85
  • 1.8 Removing and installing brake pads, brake caliper C 54-II
    87
  • 1.9 Removing and installing brake caliper C 54-II
    89
  • 1.10 Repairing front brakes, FN 3 brake caliper
    91
  • 1.11 Removing and installing brake pads, brake caliper FN 3
    93
  • 1.12 Removing and installing brake caliper FN 3
    96
  • 2 Repairing rear brakes (drum brakes)
    98
  • 2.1 Removing and installing rear brakes
    98
  • 2.2 Resetting brake
    100
  • 2.3 Repairing rear brakes
    100
  • 2.4 Removing and installing brake shoes
    101
  • 3 Repairing rear brakes (disc brakes)
    104
  • 3.1 Removing and installing brake pads
    105
  • 3.2 Removing and installing brake caliper
    108
  • 4 Assembly overview - handbrake lever
    111
  • 4.1 Removing and installing handbrake cable (drum brakes)
    111
  • 4.2 Adjusting handbrake
    113
  • 4.3 Removing and installing handbrake cable (disc brakes)
    113
  • 4.4 Adjusting handbrake
    115
  • 5 Assembly overview - brake pedal
    117
  • 5.1 Separating brake pedal from brake servo
    117
  • 5.2 Removing and installing pedal cluster
    119
  • 5.3 Removing and installing brake pedal
    119
  • 5.4 Removing and installing brake light switch F and brake pedal switch F47
    121
  • Brakes - hydraulics
    123
  • 1 Repairing front brake calipers
    123
  • 1.1 Repairing brake caliper FS II
    123
  • 1.2 Removing and installing piston for brake caliper FS II
    123
  • 1.3 Repairing FS III brake caliper
    125
  • 1.4 Removing and installing piston for FS III brake caliper
    126
  • 1.5 Repairing brake caliper C 54-II
    128
  • 1.6 Removing and installing piston for brake caliper C 54-II
    129
  • 1.7 Repairing brake caliper FN 3
    131
  • 1.8 Removing and installing piston for brake caliper FN 3
    132
  • 2 Repairing rear brake caliper
    136
  • 2.1 Removing and installing piston for rear brake caliper
    137
  • 3 Pressure leak test
    139
  • 3.1 Test prerequisites:
    139
  • 4 Assembly overview - brake pressure regulator
    140
  • 5 Checking and adjusting brake pressure regulator
    141
  • 5.1 Checking and adjusting pressure
    141
  • 6 Bleeding brake system
    143
  • 6.2 Changing brake fluid (every 2 years)
    145
  • 7 Assembly overview: Brake servo and master brake cylinder
    146
  • 7.1 Vacuum pump for brake servo (diesel vehicles) overview
    147
  • 7.2 Checking non-return valve:
    149
  • 8 Removing and installing brake master cylinder
    150
  • 8.1 Removing
    150
  • 9 Removing and installing brake servo
    152
  • 9.1 Removing
    152
  • 9.2 Installing
    154
  • 10 Repairing brake lines
    155
  • 10.1 Assembly overview - flanging tool
    155
  • 10.2 Work instructions
    156
Manufacturer's designation Brake systems
Manufacturer Volkswagen
Suitable for Polo Sedan (2003 - 2005) / Polo (2005 - 2007)
Suitable car types 9N2, 9N4
Category Reparaturanleitung

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