Brake systems Lupo 3 L, Lupo FSI, Lupo GTI

Chapter overview

• Technical data
  1
• 1 Technical data
  1
• 1.1 Technical data
  1
• 1.2 Lupo 3 L
  1
• 1.3 Lupo FSI
  2
• 1.4 Lupo GTI
  4
• Anti-locking brake system
  6
• 1 Anti-locking brake system ABS Mark 30 IE and ABS/EDL/TCS/ESP Mark 20 IE
  6
• 1.1 Anti-locking brake system ABS Mark 30 IE and ABS/EDL/TCS/ESP Mark 20 IE
  6
• 1.2 Anti-locking brake system ABS Mark 30 IE
  6
• 1.3 Anti-locking brake system ABS/EDL/TCS/ESP Mark 20 IE
  7
• 1.4 Notes for repair work on ABS Mark 30 IE and ABS/EDL/TCS/ESP Mark 20 IE
  8
• 2 Hydraulic unit, brake servo/ brake master cylinder - Assembly overview
  9
• 2.1 Hydraulic unit, brake servo/ brake master cylinder - Assembly overview
  9
• 2.3 Removing and installing control unit and hydraulic unit, ABS Mark 30 IE
  14
• 2.4 Connecting vehicle diagnosis, testing and information system VAS 5051
  18
• 2.5 Safety precautions
  19
• 2.8 Connecting vehicle diagnosis, testing and information system VAS 5051
  28
• 2.9 Safety precautions
  29
• 3 Removing and installing parts of ABS system on front and rear axles
  30
• 3.1 Removing and installing parts of ABS system on front and rear axles
  30
• 3.2 Removing and installing parts of ABS system on front axle, Lupo 3 L
  30
• 3.3 Removing and installing parts of ABS system on rear axle, Lupo 3 L
  35
• 3.4 Removing and installing parts of ABS system on front axle, Lupo FSI and Lupo GTI
  39
• 3.5 Removing and installing parts of ABS system on rear axle, Lupo FSI and Lupo GTI
  44
• 4 Removing and installing parts of ESP system
  48
• 4.1 Removing and installing parts of ESP system
  48
• 4.3 Removing and installing steering angle sender -G85
  50
• Brakes, Brake mechanics
  51
• 1 Servicing front brakes
  51
• 1.1 Servicing front brakes
  51
• 1.2 Servicing front brakes, FS I - AL, Lupo 3 L
  51
• 1.3 Removing and installing brake pads
  57
• 1.4 Servicing front brakes, Lucas brake caliper, Lupo FSI and Lupo GTI
  59
• 1.5 Removing and installing brake pads, Lucas brake caliper
  65
• 2 Servicing rear wheel brakes (drum brakes)
  67
• 2.1 Servicing rear wheel brakes (drum brakes)
  67
• 2.2 Removing and installing rear wheel brakes, Lupo 3 L
  68
• 2.3 Releasing brake shoe adjustment
  73
• 2.4 Servicing rear wheel brakes
  73
• 2.5 Removing and installing brake shoes
  76
• 2.6 Removing and installing handbrake cable
  79
• 2.7 Adjusting handbrake
  81
• 3 Servicing rear wheel brakes, disc brakes
  82
• 3.1 Servicing rear wheel brakes, disc brakes
  82
• 3.2 Servicing rear wheel brakes, Lupo FSI and Lupo GTI
  83
• 3.3 Removing and installing brake pads
  88
• 3.4 Removing and installing handbrake cable
  91
• 3.5 Adjusting handbrake
  93
• 4 Handbrake lever - Assembly overview
  94
• 4.1 Handbrake lever - Assembly overview
  94
• 5 Brake pedal/brake servo - Assembly overview
  96
• 5.1 Brake pedal/brake servo - Assembly overview
  96
• 5.2 Vehicles with mechanical steering, Lupo 3 L
  96
• 5.3 Separating brake pedal from brake servo
  99
• 5.4 Removing and installing brake pedal
  100
• 5.5 Vehicles with electro-mechanical power assisted steering, Lupo 3 L
  102
• 5.6 Separating brake pedal from brake servo
  105
• 5.7 Removing and installing brake pedal
  106
• 5.8 Removing and installing mounting bracket
  108
• 5.9 Vehicles with mechanical and hydraulic steering, Lupo FSI and Lupo GTI
  113
• 5.10 Separating brake pedal from brake servo
  116
• 5.11 Removing and installing brake pedal
  117
• Brakes, Brake hydraulics
  119
• 1 Servicing front brake calipers
  119
• 1.1 Servicing front brake calipers
  119
• 1.2 Brake caliper FS I - AL, Lupo 3 L
  119
• 1.3 Removing and installing front brake caliper piston
  121
• 1.4 Brake caliper from Lucas, Lupo FSI and Lupo GTI
  124
• 1.5 Removing and installing front caliper piston
  127
• 2 Servicing rear brake caliper
  130
• 2.1 Servicing rear brake caliper
  130
• 2.2 Removing and installing rear brake caliper piston
  133
• 2.3 Pressure leak test
  135
• 3 Bleeding braking system on vehicles with and without ABS
  136
• 3.1 Bleeding braking system on vehicles with and without ABS
  136
• 3.2 Bleeding brake system with brake filling and bleeder unit V.A.G 1869
  136
• 3.3 Bleeding brake system without brake filling and bleeding appliance
  137
• 4 Assembly overview: brake master cylinder/brake servo
  138
• 4.1 Assembly overview: brake master cylinder/brake servo
  138
• 4.2 Checking non-return valve
  141
• 4.3 Removing and installing pressure sensor for gearbox
  141
• 5 Assembly overview: Brake master cylinder/brake servo for vehicles with ABS/EDL/TCS/ESP
  142
• 5.1 Assembly overview: Brake master cylinder/brake servo for vehicles with ABS/EDL/TCS/ESP
  142
• 5.2 Removing and installing brake pressure sender of brake master cylinder
  146
• 6 Removing and installing brake master cylinder
  147
• 6.1 Removing and installing brake master cylinder
  147
• 7 Removing and installing brake servo
  148
• 7.1 Removing and installing brake servo
  148
• 8 Definitions
  150
• 8.1 Definitions
  150