Volkswagen Eos 2006 User Manual

Service

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Braker systems

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Edition,05.2008

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Service Department. Technical Information

Service

List of Workshop Manual Repair GroupsList of Workshop Manual Repair GroupsList of Workshop Manual Repair Groups

Repair Group

00 - Technical data

45 - Anti-lock brake system

46 - Brakes - mechanism

47 - Brakes - hydraulics

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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 © 2010 Volkswagen AG, Wolfsburg

K0058970520

Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003

Brake systems - Edition 05.2008

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1	Brake allocation via PR No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1
1.1	Front brakes, Touran . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1
1.2	Front brakes, Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1
1.3	Front brakes, Eos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2
1.4	Rear brakes, Touran . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2
1.5	Rear brakes, front-wheel drive Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3
1.6	Rear brakes, four-wheel drive Golf . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4
1.7	Rear brakes, Eos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4
2	Technical data for brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5
2.1	Brake master cylinder and brake servo, Touran . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5
2.2	Brake master cylinder and brake servo, Golf, Eos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5
2.3	Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5
2.4	Rear brakes (disc brakes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	7
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

45 - Anti-lock brake system .										.	.	.		.	.		.	.		.	. .	. .	. . . .	.	.	.	.	.	.	.	.		.		.	.		.	.		. .	. .			.			.			.			.	. . . . . . . .	11
1	General notes on anti-lock brake system																						V.ol.ks.w.	a.g	. .	.	.	. .		.	.	.		.	.		.	.	.	.	. .	.	.		.		.			.		.			. . . . . . . . . .	11
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2	Notes for repair work on anti-lockl																				en	A				A																														12
																				brake system					. .	.	G.	d. .		.	.	.		.	.		.		.	.	. .	. .		.			.	.			.			.	. . . . . . . . .
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	Connecting VAS 5051 and selecting functions																							.	. . .		.	. .		.	.	.		.			.	.	.	.	. .	.	.		.		.			.		.			. . . . . . . . . .
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4								o																															e		r															15
	Electrical/electronicucomponents and fitting locations																											. .		.	.	.		.	.		.		.	e. .		. .	.				. .				.			.	. . . . . . . . .
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4.1 ABS Mark 70 (ABS/TCS)le													.	.	.	.		.	.	.	. .	. .	. . . . .	.	. . .		.	. .		.	.	.		.	.		.	.	.	.	. .	.p. .					. .					.			. . . . . . . . . .
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4.2 ABS Mark 60 (ABS/EDL/TCS/ESP)d																					.	. .	. . . . .	.	. . .		.	. .		.	.	.		.	.		.	.	.	. .	.	.	. .		y. .							.			. . . . . . . . . .
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4.3 ABS Mark 60m							(ABS/EDL/TCS/ESP) up to week 22/2008																																								l									19
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4.4			e	r			(ABS/EDL/TCS/ESP) from week 22/2008																																											i						21
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	ABS Markt60p																													.	.	.		.	.		.		.	. .	.	. .	.				. .				w. . . . . . . . . . .
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5	n				via warning lamps																																																i			23
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	Fault displayis																		.	.	. .	. . .	. . . .	. .	. .		. .	. .		.		.	.	.	.		.	.		. . .		. .	.			.	.				.		.
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6	e	overview - hydraulic unit, brake servo/brake master cylinder																																																					s	26
	Assemblyh																																									.	.				. .						.		.e. . . . . . . .
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6.1 ABS Marki													.	.	.	.		.	.	.	. .	. .	. . . . .	.	. . .		.	. .		.	.	.		.	.		.	.	.	. .	.	.	. .				. .					.			. c. . . . . . . . .
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6.2 ABS Mark 60 (ABS/EDL/TCS/ESP)																																																							o	33
																					.	. .	. . . . .	.	. . .		.	. .		.	.	.		.	.		.	.	.	. .	.	.	. .				. .					.			. . . . . . . . . .
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6.3 ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 22/2008																														.		.	.		. .			.	.	. .	.	. .	.				. .				.				. . o. . . . . . . .
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6.4 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 22/2008																														.	.	.		.	.		.		.	. .	.	. .	.				. .				.			.
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7	e		and installing parts of ABS system on front and rear axle																																																					56
	Removingo																																								.	. .	.				. .						.		. . . . . . . . .e
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	p		and installing parts of ABS system on front axle																																																				s	56
7.1 Removingp																																	.		. .		.		.	. .	.	. .	.				. .				.				. .f. . . . . . . .
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	Removing and installing parts of anti-lock brake system on rear axle (front-wheel drive) . .
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	Removing and installing parts of anti-lock brake system on rear axle (four-wheel drive) . .
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	Removingcand installing parts of ESP system																							. .	. .		. .	.	.	.		.	.		. .		.		.	. .	.	. .	.				. .				.				.i . . . . . . . . .
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8.1 Removing and installing ESP sensor unit G419 (Touran)																															.	.		.	.		.	.	.	. .	.	.	. .				. .					.			. . . . . . . . . .
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	Removing andr installing ESP sensor unit G419 (Golf, Eos)																																.		.	.		.	.	. .	.	. .	.				o. .	d			.				. . . . . . . . . .
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8.3 Removing and installing steering angle sender G85																												. .	.	.		.	.		. .		.		.	. . .		. .	.	u		.	.				.		.		. . . . . . . . . .
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8.4 Removing and installing brake servo vacuum sender G483																																		.	.		.	.		. . .		.n.	.			.	.				.		.		. . . . . . . . . .
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.46 - Brakes - mechanism . .. r.y													.		.	.		.	.	.	.	. .	. . . .	.	. .		.	. .		.		.		.	. .b				.r. .		.	.	.				. .						.		. . . . . . . .	63
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	Repairing front brakes . . . . . d.e.t																		.	.	. .	. . .	. . . .	.	. . .		.				k.l.			.	.		.	.	.	. .	.	.	. .				. .					.			. . . . . . . . . .
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1.1 Repairing front brakes, FS III brake caliper . .																								. .	. .		. .	.	.	.		.	.		. .		.		.	. .	.	. .	.				. .				.				. . . . . . . . . .
1.2 Removing and installing brake pads/linings . .																								.	. .		.	. .	.		.	.		.	.	.		.	.	. .	.	. .	.				. .				.				. . . . . . . . . .	64
1.3 Removing and installing brake caliper																						. .	. . . .	. .	. .		.	. .	.		.	.		.	.	.		.	.	. .	.	. .	.				. .				.				. . . . . . . . . .	67
1.4 Repairing front brake, FN 3 brake caliper																							. . . .	.	. . .		.	. .		.	.	.		.	.		.	.	.	. .	.	.	. .				. .					.			. . . . . . . . . .	69
1.5 Removing and installing brake pads/linings . .																								.	. .		.	. .	.		.	.		.	.	.		.	.	. .	.	. .	.				. .				.				. . . . . . . . . .	72

Contents i

Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003

Brake systems - Edition 05.2008

1.6	Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	75
1.7	Repairing front brake, FNR-G brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	77
1.8	Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	78
1.9	Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	81
2	Repairing rear brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	84
2.1	Repairing rear brake CI 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	84
2.2	Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	85
2.3	Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	87
2.4	Repairing rear brake CII 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	89
2.5	Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	91
2.6	Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	93
2.7	Repairing rear brake CII 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	95
2.8	Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	97
2.9	Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	99
2.10	Adjusting handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	101
3	Assembly overview - handbrake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	103
3.1	Removing and installing handbrake cable up to model year 2007 . . . . . . . . . . . . . . . . . . . .	103
3.2	Removing and installing handbrake cable from model year 2008 . . . . . . . . . . . . . . . . . . . .	106
4	Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	109
4.1	Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	109
4.2	Removing and installing brake light switch F from week 45 of 2005 . . . . . . . . . . . . . . . . . .	110

47 - Brakes - hydraulics . . .		. . .	.			.		.			.		.	.	.	. . .		. .	.		.	.		.	.	e.n.AG. .V.		.	.w.ag.e.nA.		.	.		.	.			.	.	.	.		.	. . .	.	.	113
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1	Repairing front brake caliper																		yV		lk																	t.g											113
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1.1	Repairing brake caliper FS III															o		d																						a			e						113
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1.2																th																																	113
	Removing and installing piston for brake caliper FS III																										. . . .	. . .	. .	. .	. .		.	.	.		.		. .	.	.		.	. . . . .a		.
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1.3	Repairing brake caliper FN 3								. . .n					s																															c				115
														.	. .	. . .	.	.	. .		.		.	.	.	.	. . . . .	. .	. . .	. .	. .		.	.		.	.		.	. .	.		.	. . .	. .t.
													le																																e
1.4													u	brake caliper FN 3																															p
																																														a
	Removing and installing piston fore																										. . . .	. . .	. . .	. .	.	.		.	.		.		. .	.	.		.	. . .	. .	.y116
										t	t	d																																		n
									i																																							l
1.5																																																i
																																																a
	Repairing FNR-G brake caliperr												. .	.	.	. . .	.	.	. .		.	.	.		.	.	. . . . .	. .	. . .	. .	. .		.	.	.		.		.	. .	.		.	. . .	. .	.			119
							e	m																																									b
																																																				t
																																																			i
1.6	Removing and installing piston for FNR-G brake caliper																																																		l
																												. .	. . .	. .	. .			.	.	.	.		.	.	.	.		. . .	. .	.			120
					t	p																																														i
				o																																																y
			n																																																			i
2	Repairing rear brake caliper, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .																																																			w
																																																	124e
		s																																																				t
		i																																																				r
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2.1	Removing	e																																															126						s
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		l																																																					p
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2.2	Installing																																																127							t
		.i. . .			.			.		.		.	.	.	. .	. . .	.	.	. .		.		. .		.	.	. . . .	. . .	. . .	. .	. . .			.		. .		.		. .	.	.		. . .	. .	.										c
		n																																																						t
2.3	Pre-bleeding brake calipert				.			.	.			.	.	.	. .	. . .	.	.	. .		. .		.		.	.	. . . .	. . .	. . .	. .	. . .			.	.	.		.		. .	.	.		. . .	. .	.			128							h
		r																																																						o
		o																																																						t
3	Pressurised leak test	r																																															129							e
		a. . .		.			.	.			.		. .		. .	. . .	.	.	. .	.	. .		.		.	.	. . . . .	. .	. . .	. .	. . .			.	.	.		.		. .	.	.		. . .	. .	.										r
																																																								c
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3.1	Test prerequisites:	n																																															129							t
		i. . .			.		.		.		.		.	.	. .	. . .	.	.	. .	.	. .		.		.	.	. . . . .	. .	. . .	. .	. . .			.	.	.		.		. .	.	.		. . .	. .	.
																																																								r
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4		s																																															130
	Bleeding brake system p. . .					.		.			.	.	.	.	. .	. .	.	. .	.	.	.		.		.	.	. . . . .	. .	. . .	. .	. . .			.	.	.		.		. .	.	.		. . .	. .	.										s
		o																																																						e
4.1		r																																																						s
	Bleeding brake system using brake filling and bleeding equipment VAS 5234 or V.A.G 1869																																																							o
		u																																																						f
		p																																															131
	. . . . . . . . . . . . . . . . .	.c. . .				.		.			.	.	.	.	.	. . .	.	. .	.	.	. .		.		.	.	. . . . .	. .	. . .	. .	. . .			.	.	.		.		. .	.	.		. . .	. .	.										f
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4.2	Changing brake fluid	r																																															132
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		e																																																						r
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		m
5	Brake servo and master brake cylinder .																.	.	. .	.	. .		.		.	.	. . . . .	. .	. . .	. .	. . .			.	.	.		.		. .	.	.		. . .	. .	.			133n
																																																						i
		o																																																				o
5.1				r																																																	n	i
					o
	Assembly overview - brake servo/brake master cylinder (left-hand drive vehicle)																																								.	.		. . .	. .	.			133h
		c																																																		t
																																																		s	i
							t
								a
5.2						e																																											134
	Assembly overview - brake servo/brake master cylinder (right-hand drive vehicle)																																									.		. .	. .	.
									r																																							o	d
								v
5.3								i								servo (diesel vehicles)																														m.	c		136
											p
	Overview - exhauster pump for brakef																												. . .	. .	. .		.		.	.	.		.	.	.	.		. . .	. .
												r																																		u
												o																																	e
5.4	Checking non-return valve												g																																				137
							. . . . . .y.									. . .	.	.	. .	.	. .		.		.	.	. . . .	. . .	. . .	. .	. .			.	.	.		.	.	.	.	.		. . ..	.n.	.
														n
														i																														C	t
5.5															p						sensor G294																												137
	Removing and installing brake servo pressure.t																											.	. . .	. .	. .		.		.	. .			.	.	.	.	r. . .		. .	.
															o																													o
																C																												p
																																											y
																h																										g
5.6	Vacuum pump for brakes V192															g		y.p																					y		h		i						137
													.	.	. .				.	. .	. .		.		.	.	. . . .	. . .	. . .	. .	. .		.	.		. .		.						. . .	. .	.
																	i																								t
																	r
																			o																					b
																																							V
5.7																			c													ga.w						o											138
	Removing and installing brake light switch F as ofdetweek 45/05																												. . .	. .	. .					k.l .				. .	.	.		. . .	. .	.
																				y
																					b			c	et	or					e				s
																															n
																														A
6	Removing and installing brake master cylinder																										P			G																			139
																					. .		.		.	.	. . . . .	. .	. . .	. .	. . .			.	.	.		.		. .	.	.		. . .	. .	.
6.1	Removing . . . . . . . . .	. . . .				.		.			.	.	.	.	. .	. .	.	. .	.	.	. .		.		.	.	. . . . .	. .	. . .	. .	. . .			.	.	.		.		. .	.	.		. . .	. .	.			139
6.2	Installing . . . . . . . . . .	. . . .			.			.		.		.	.	.	. .	. . .	.	.	. .	.	. .		.		.	.	. . . .	. . .	. . .	. .	. . .			.		. .		.		. .	.	.		. . .	. .	.			140
7	Removing and installing brake servo															. . .	.	.	. .	.	. .		.		.	.	. . . .	. . .	. . .	. .	. . .			.	.	.		.		. .	.	.		. . .	. .	.			141
7.1	Removing . . . . . . . . .	. . . .				.		.			.	.	.	.	. .	. .	.	. .	.	.	. .		.		.	.	. . . . .	. .	. . .	. .	. . .			.	.	.		.		. .	.	.		. . .	. .	.			141
7.2	Installing . . . . . . . . . .	. . . .			.			.		.		.	.	.	. .	. . .	.	.	. .	.	. .		.		.	.	. . . .	. . .	. . .	. .	. . .			.		. .		.		. .	.	.		. . .	. .	.			143

ii Contents

	Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003
	Brake systems - Edition 05.2008
8	Brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	144
8.1	Separating point on underbody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	144
8.2	Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	144

.

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Contents iii

Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003 Brake systems - Edition 05.2008

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iv Contents

Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003

Brake systems - Edition 05.2008

00 – Technical data

1Brake allocation via PR No.

The type of brake system installed in the vehicle is indicated among other things by the corresponding PR number on the ve hicle data sticker.

Example of a vehicle data sticker:

In this example the vehicle is equipped with the following brakes:

♦Arrow 1 - Rear brakes -1KQ

♦Arrow 2 - Front brakes -1ZE

The vehicle data sticker can be found in the spare wheel well and in the service booklet.

♦Allocation Electronic Parts Catalogue (ETKA) .

♦The following tables explain the PR numbers. These are rel evant for the brake caliper/brake disc and brake pads.

G.

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1.1te

Front brakes, Touran

p

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Engine

PR No.

Front brake

b

y

t

l

t

i

n

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is

1.6 l - 75 kW

1ZE

FN3 (15”)

i

r

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t

,

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1.6 l - 85 kW FSI

s

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1.4 l - 103 kW FSI

t

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2.0 l -110 kW FSI

e

r

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t

t

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a

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1.9 l - 66 kW TDI

i

r

p

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n

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1.9 l - 74, 77 kW TDI

e

c

s

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s

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2.0 l - 100, 103 kW TDI

e

r

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p

s

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1.4 l -125 kW FSI

1LJ

FN3 (16”)

n

i

p

f

l

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2.0 l - 125 kW TDI

o

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n

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Engine

PR No.

Front brake

d

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1ZP

FN3 (15”)

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1.6fl - 85 kW FSI

u

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n

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2.0 l -110 kW

t

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1.2

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brakes, Golf

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PR No..

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Front brake

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P

A

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1.4 l - 55, 59 kW

1ZF1) / 1ZM

FS III (15”)

1.4 l -66 kW FSI

1.6 l - 75 kW

1.6 l - 85 kW FSI2)

2.0 l - 85 kW

1.9 l - 66 kW TDI

1. Brake allocation via PR No. 1

Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003 Brake systems - Edition 05.2008

1.9 l - 77 kW TDI 3)
2.0 l -55 kW SDI
1.6 l - 85 kW FSI4)	1ZE	FN3 (15”)
1.4 l - 88, 90 kW FSI
1.4 l - 103, 110 kW FSI
2.0 l -110 kW FSI
1.9 l - 77 kW TDI 5)
2.0 l - 100, 103 kW TDI
2.0 l -147 kW FSI	1LJ / 1LL	FN3 (16”)
1.4 l -125 kW FSI	1LJ
2.0 l - 125 kW TDI
3.2 l -184 kW	1LM	FNR-G (17”)

1)the 1ZE brake was installed at the start of series production.

2)Golf

3) with 5-speed manual gearbox 0A4.

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Engine

PR No.

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Front brake

1.6 l -75 kW

1ZP

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FN3 (15”)

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1.6 l - 85 kW FSI

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2.0 l -110 kW

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2.5 l -110 kW

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1.9 l - 74 kW TDI

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2.0 l -147 kW FSI

1ZDi/ 1LV

FN3 (16”)

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1.3

Front brakes,

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PR No.

Front brake

p

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1.6 l - 85 kW FSI

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FN3 (15”)

1ZEm

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2.0 l -110 kW FSI

c

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2.0 l -147 kW FSI

1LJ

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FN3 (16”)

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2.0 l - 100, 103 kW TDI

p

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3.2 l -184 kW

n

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PR No.

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2.0 l -147 kW FSI

1ZD

FN3 (16”)

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3.2 l -184 kW

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1.4Rear brakes, Touran

Engine	PR No.	Rear brake
1.6 l - 75 kW	1KF	CII 41 (15”)
1.6 l - 85 kW FSI
1.4 l -103 kW FSI
2.0 l -110 kW FSI
1.9 l - 66 kW TDI

2Rep. Gr.00 - Technical data

		Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003
							Brake systems - Edition 05.2008
1.9 l - 74, 77 kW TDI
2.0 l - 100, 103 kW TDI
1.4 l -125 kW FSI		1KJ 1)			CII 41 (16”)
2.0 l - 125 kW TDI
1) Gradual switch to 1KF from the end of 2006
Country-specific brake for Japan:
Engine		PR No.			Rear brake
1.6 l - 85 kW FSI		1KE			CII 41 (15”)
2.0 l -110 kW

1.5Rear brakes, front-wheel drive Golf

Without Golf Variant:

Engine

PR No.

Rear brake

1.4 l - 55, 59 kW

1KQ / 1KD

CI 38 (15”)

1.4 l - 66 kW FSI

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1.6 l - 75 kW

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1.6 l - 85 kW FSI

i

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2.0 l - 85 kW

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1.4 l - 88, 90 kW FSI

n

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1.4 l - 103, 110 kW FSI

m

i

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2.0 l -110 kW FSI

i

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n

w

2.0 l - 55 kW SDI

s

i

t

h

i

r

,

e

e

s

l

p

1.9 l - 66 kW TDI

o

h

e

1.9 l - 77 kW TDI

w

c

t

n

t

i

o

r

t

2.0 l - 100, 103 kW TDI

o

h

t

e

r

a

c

2.0 l - 147 kW FSI

p

1KY

CII 38 (16”)

o

n

r

r

i

,

e

1.4 l - 125 kW FSI

s

1)

c

e

1KZ

t

n

s

o

e

p

s

2.0 l - 125 kW TDI

r

s

u

o

p

f

l

i

a

n

i

1)

c

f

o

r

e

r

Gradual switch to 1KD from the end of 2006

m

m

a

m

Golf Variant only:

o

i

i

n

o

c

n

Engine

r

Rear brake

t

o

e

i

h

t

PR No.

d

s

a

1.6 l - 75 kW

v

CII 41 (15”)

o

i

r

c

1KFp

u

r

m

1.6 l - 85 kW FSI

o

f

e

g

n

n

i

t

y

.

C

2.0 l - 110 kW FSI

p

o

o

C.

p

y

t

r

h

i

g

1.9 l - 74, 77 kW TDI

g

h

i

t

r

yp

b

o

c

y

y

V

o

kl

2.0 l - 100, 103 kW TDI

b

d

s

w

et

cetor

a

Aneg

P

.G

Country specific brake for North America / Japan:

Engine	PR No.	Rear brake
1.6 l - 75 kW	1KE	CII 41 (15”)
1.6 l - 85 kW FSI
2.0 l -110 kW
2.5 l - 110 kW
2.0 l - 147 kW FSI
1.9 l - 77 kW TDI
2.0 l - 100, 103 kW TDI

1. Brake allocation via PR No. 3

Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003

Brake systems - Edition 05.2008

2.0 l - 147 kW FSI

1KV

CII 38 (16”)

1.6Rear brakes, four-wheel drive Golf

Engine

PR No.

Rear brake

2.0 l - 110 kW FSI

1KF

CII 41 (15”)

1.9 l - 77 kW TDI

2.0 l - 100, 103 kW TDI

3.2 l - 184 kW

2EL

CII 41 (17”)

Country-specific brake for Japan:

Engine

PR No.

geRearnA

brake

nAG

o

.V lkswa

ge

a

G

d

o

e

s

w

s

n

2.0 l - 110 kW

1KE

lk

CII 41 (15”)

ot

b

o

gu

V

d

y

a

e

r

s

a

i

n

r

t

1.7

Rear brakes,aEos

e

a

th

e

u

o

r

s

c

s

c

le

e

Engine

d

n

PR No.

Rear brake

t

n

u

p

e

a

t

l

1.6 l - 85 kW FSI

i

t

1KD

CI 38 (15”)

y

m

i

b

r

a

i

e

t

2.0 l - 110 kW FSI

t

p

l

w

i

o

y

i

2.0 l - 100, 103 kW

n

e

,TDIi

s

t

e

h

s

r

l

1KZ

CII 38 (16”)

e

2.0 l - 147 kW FSIh

o

p

w

t

3.2 l - 184 kW

r

c

o

n

t

i

o

t

t

for North America / Japan:

h

Country specific brakep

o

r

e

a

c

n

r

Engine

i

PR No.

Rear brake

r

e

t

,

e

s

c

n

s

1KJ

CII 41 (16”)

2.0 l - 147 kW FSIr

s

o

e

p

s

o

3.2 l - 184 kW

u

i

a

p

f

i

n

l

f

r

o

c

r

e

m

m

a

t

m

i

o

i

n

o

c

n

r

t

o

t

s

i

h

a

e

r

o

d

v

i

c

p

u

r

m

f

o

e

g

n

n

i

t

p

.

C

y

o

o

C

p

y

.

t

r

h

g

g

h

i

i

t

r

y

b

p

y

o

c

y

V

o

kl

b

d

e

s

w

a

t

c

et

g

or

e

A

n

P

.G

4Rep. Gr.00 - Technical data

Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003

Brake systems - Edition 05.2008

2Technical data for brakes

2.1	Brake master cylinder and brake servo,
	Touran
Brake master cylinder			in mm	22
Brake servo (LHD)			in inches	11
Brake servo (RHD)			in inches	7 / 8
2.2	Brake master cylinder and brake servo,
	Golf, Eos
Brake master cylinder			in mm	22
Brake servo (LHD)			in inches	10
Brake servo (RHD)			in inches	7 / 8

2.3Front brakes

2.3.1Front brakes FS III

Item PR No.

1ZF / 1ZM

1Brake caliper

2

Brake pad,

mm

thickness

Brake pad, wear

mm

limit without

back plate

.

enAG

g

3

Brake disc

V

a

in

w

lk

s

e

y

o

mm

b

is

d

r

mm

Brake disc,

o

th

u

a

thicknesss

le

s

n

mm

dBrake disc,

e

u

it

wear limit

m

t

4p

e

r

Brake caliper

in

t

piston

mm

n

o

s

i

,

e

l

o

h

w

n

i

r

o

t

r

a

p

n

i

,

s

e

s

o

p

r

u

p

l

a

i

c

r

e

m

m

o

c

r

o

e

t

a

v

i

r

p

r

o

f

g

n

i

y

p

o

C

.

t

h

g

i

r

y

p

o

c

y

b

d

et

c

et

or

P

		FS III (15”)
		14
		2
V	olks
	wag
		en
		A
		G
		d			not
		280
		o
			e
				s		g
						u
						a
						r
						a
						n
		22				t	or
						e
							e
							a
							c
							c
		19					e
							n
							p
							t
							a
							y
							l
							i
		54					a
							b
							i
							l

t

n

d

s

i

h

o

c

u

m

e

n

t

.

C

o

p

y

r

i

g

h

t

b

y

V

o

kl

s

w

a

g

e

A

n

.G

i

	e
	s
	p
	e
	c
	t
	t
	o
	t
	h
	e
	c
	o
	r
	r
	e
	c
	t
	n
	e
	s
	s
	o
	f
	i
	n
	f
	o
	r
	m
	a
	t
	i
n	o

2. Technical data for brakes 5

o

G.

V

lksw

ag

en

en

A

A

g

G

d

o

a

e

w

s

s

n

lk

ot

o

V

g

y

b

u

d

a

e

r

s

a

i

n

r

t

Eos 2006 , Golf 2004 u

o

e

, Golf Plus 2005 , Touran 2003

r

th

e

o

a

a

s

c

Brake systems - Editionle 05.2008

p

s

c

n

e

u

t

d

a

e

n

2.3.2

Front brakesr m

FN 3

i

t

t

t

p

e

Item

PR No.

o

1ZE / 1ZP

n

s

1

Brake caliper

i

FN3 (15”)

l

,

e

o

2

Brake pad,

h

mm

14

w

thickness

n

o

i

r

mm

2

Brake pad, weara

t

limit without

r

i

p

back plate

n

e

,

s

3

Brake disc

s

in

288

r

o

p

mm

p

Brake disc,

u

mm

25

r

l

a

i

thickness

c

m

Brake disc,

e

cmm

22

m

wear limit

o

e

r

4

Brake caliper

o

54

in

t

a

v

piston

i

mmo

r

p

r

f

g

n

t

i

Item

PR No.

p

1LJ / 1LL / 1ZD / 1LV

.

p

C

y

o

o

C

y

.

r

t

h

g

1

Brake caliper

g

yp

FN3 (16”)

y

h

i

i

t

r

o

c

y

V

b

o

2

Brake pad,

mm

b

14etc

ega

s

thickness

d

et

or

A

n

w

P

.G

Brake pad, wear

mm

2

limit without

back plate

3

Brake disc

in

312

mm

Brake disc,

mm

25

thickness

Brake disc,	mm	22
wear limit
4 Brake caliper	in	54
piston	mm

2.3.3Front brakes FNR-G

Item	PR No.		1LK / 1LM
1	Brake caliper		FNR-G (17”)
2	Brake pad,	mm	14
	thickness
	Brake pad, wear	mm	2
	limit without
	back plate
3	Brake disc	in	345
		mm
	Brake disc,	mm	30
	thickness
	Brake disc,	mm	27
	wear limit
4	Brake caliper	in	57
	piston	mm

6Rep. Gr.00 - Technical data

Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003

Brake systems - Edition 05.2008

2.4Rear brakes (disc brakes)

2.4.1Rear brakes CI 38

o

G.

V lksw

ag

en

Item

PR No.

en

A

A

G

d

/ 1KD

g

a

lksw

oe1KQs

o

n

ot

V

g

y

1

b

caliper

u

d

a

e

r

s

a

Brakei

CI 38 (15”)n

r

t

o

e

th

e

o

2

u

Brake pad,

mm

11

r

a

a

s

thickness

c

les

c

e

n

p

u

Brake pad, wear

mm

2

t

d

a

t

e

n

y

i

t

limit without

l

m

i

r

a

b

e

back plate

i

p

l

i

t

t

o

y

3

Brake disc

in

255

n

w

s

i

t

h

mm

r

i

,

e

e

s

l

p

o

Brake disc,

mm

10

h

e

w

c

thickness

t

n

t

i

o

r

t

o

Brake disc,

mm

8

h

t

e

r

a

wear limit

c

p

o

n

r

r

i

,

4

Brake caliper

in

38

e

s

c

e

t

s

piston

mm

n

o

e

p

s

r

s

u

o

p

f

l

i

a

2.4.2

Rear brakes CII 38

n

i

c

f

o

r

e

r

m

m

a

m

Item

PR No.

1KY / 1KZ / 1KV

t

o

i

i

n

o

c

1

Brake caliper

CII 38 (16")

n

r

t

o

e

s

i

h

t

d

a

2

Brake pad,

mm

11

v

c o

i

r

p

u

r

thickness

m

o

f

e

g

n

Brake pad, wear

2

n

i

t

y

.

C

p

o

o

C

p

y

.

r

limitt

without

i

h

g

g

h

i

t

r

backypplate

b

y

o

c

y

V

o

kl

3

b

d

in

s

286

w

Brake discetc

et

or

ega

A

n

P

mm

.G

Brake disc,

mm

12

thickness

Brake disc,

10

wear limit

4

Brake caliper

in

38

piston

mm

2. Technical data for brakes 7

Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003 Brake systems - Edition 05.2008

2.4.3Rear brakes CII 41

Item	PR No.		1KF / 1KE
1	Brake caliper		CII 41 (15")
2	Brake pad,	mm	11
	thickness
	Brake pad, wear	mm	2
	limit without
	back plate
3	Brake disc	in	260
		mm
	Brake disc,	mm	12
	thickness
	Brake disc,	mm	10
	wear limit
4	Brake caliper	in	41
	piston	mm

Item PR No.

1Brake caliper

2	Brake pad,	mm
	thickness
	Brake pad, wear	mm
	limit without
	back plate
3	Brake disc	in
		mm
	Brake disc,	mm
	thickness
	Brake disc,	mm
	wear limit
4	Brake caliper	in
	piston	mm

Item PR No.

1Brake caliper

2	Brake pad,	mm
	thickness
	Brake pad, wear	mm
	limit without
	back plate
3	Brake disc	in
		mm
	Brake disc,	mm
	thickness
	Brake disc,	mm
	wear limit
4	Brake caliper	in
	piston	mm

1KJ

CII 41 (16")

11

2

.

n

AG

wage

s

lk

o

V

y

b

d

e

is

r

286

o

a

th

u

s

s

le

12

d

u

n

e

t

m

i

t

10

p

e

r

t

n

o

s

i

41l

,

e

o

h

w

n

i

r

2ELr / 2EA

o

t

a

CIIi41 (17")

p

n

s11

,

s

e

o

p

r

l2

u

p

a

i

c

r

e

m

310c

m

o

	r
	o
22	e
	i
	t
	a
	v
	r
	p
	r
	o
20	f
	y
	g
	n
	i
	p
	o
	C
	.
	t
41	h	yp
	g
		i
		r	o
			c
			y
			b
			d
			et
			c
			et
			or
			P

V

olk

s

wag

en

A

G

d

o

e

s

n

ot

g

u

a

r

a

n

t

e

e

o

r

a

c

c

e

p

t

a

n

y

l

i

a

b

i

l

i

t

y

w

i

t

h

r

e

s

p

e

c

t

t

o

t

h

e

c

o

r

r

e

c

t

n

e

s

s

o

f

i

n

f

o

r

m

a

t

i

n

i

n

o

t

d

s

i

h

o

c

u

m

e

n

t

.

C

o

p

y

r

i

g

h

t

b

y

V

o

kl

s

w

a

g

e

A

n

.G

8Rep. Gr.00 - Technical data

Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003

Brake systems - Edition 05.2008

3Brake test

3.1General

♦The drive is provided by the roller dynamometer.

♦For the test, ensure for vehicles with a manual gearbox that the gear lever is in neutral and for vehicles with an automatic gearbox, that the selector lever is in “N”.

♦For test, observe specifications provided by manufacturer of roller dynamometer.

Note

The brake regulation systems do not function when ignitione

is off.

o

.V lk

g

n

AG

a

w

s

lk

o

V

3.2

y

Test for vehicles with front-wheel drive

b

d

e

is

r

o

th

u

a

The brake test must be performed on as single-axle roller dyna

le

s

mometer.

e

d

un

t

The maximum test speed must not exceed 6 km/h.

m

i

t

r

e

fulfil these requirements.

The test rigs authorised by Volkswagent

o

p

s

n

3.3

with four-wheel drive

Test for vehiclesl

i

,

e

o

coupling

via a Haldexw

h

n

i

r

o

t

r

3.3.1

a

The brake,test should be performed on

p

n

i

roller dynamometer with

a single-axles

s

e

contra-rotating rollers for four-wheel

o

p

r

u

drive vehicles.

p

l

a

i

c

r

Contra-rotating means that themdynamometer rollers are driven

e

m

forwards on one side and backwards on the opposite side.

o

c

r

This prevents brake forces beingatransferred to the drive train.

o

e

t

v

during the test, which

The forward rotating wheel is measuredo

i

r

p

r

means two brake tests per axle must be performed.

f

g

n

i

y

p

The maximum test speed must not exceedC.t6 km/h.

o

h

g

i

r

requirements.

The test rigs authorised by Volkswagen fulfil theseoc

y

p

3.3.2If no test rig is available for fourbdetc-ewheeltorP drivevehicles,thebraketestcanalsobe

carried out on a standard single-axle roller dynamometer as follows:y

s

wag

en

A

G

d

o

e

s

n

ot

g

u

a

r

a

n

t

e

e

o

r

a

c

c

e

p

t

a

n

y

l

i

a

b

i

l

i

t

y

w

i

t

h

r

e

s

p

e

c

t

t

o

t

h

e

c

o

r

r

e

c

t

n

e

s

s

o

f

i

n

f

o

r

m

a

t

i

n

i

n

o

t

d

s

i

h

o

c

u

m

e

n

t

.

C

o

p

y

r

i

g

h

t

b

y

V

o

kl

s

w

a

g

e

A

n

.G

–Drive vehicle forwards onto the rollers.

–Switch engine off and wait for 2 seconds.

–Carry out front brake test.

–Start engine and wait for approx. 5 seconds until sufficient vacuum has been built up.

–Drive vehicle forwards until rear wheels are positioned on roll ers.

3. Brake test 9

Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003 Brake systems - Edition 05.2008

–Switch engine off and wait for 2 seconds.

–Carry out rear brake test.

–Start engine and wait for approx. 5 seconds until sufficient vacuum has been built up.

.

enAG

g

a

w

s

lk

o

V

y

b

d

e

is

r

o

th

u

a

s

s

le

d

u

n

e

t

t

m

i

r

p

e

t

o

n

s

i

,

e

l

o

h

w

n

i

r

o

t

r

a

p

n

i

,

s

e

s

o

p

r

u

p

l

a

i

c

r

e

m

m

o

c

r

o

e

t

a

v

i

r

p

r

o

f

g

n

i

y

p

o

C

.

t

h

g

i

r

y

p

o

c

y

b

d

et

c

et

or

P

V

olk

s

wag

en

A

G

d

o

e

s

n

ot

g

u

a

r

a

n

t

e

e

o

r

a

c

c

e

p

t

a

n

y

l

i

a

b

i

l

i

t

y

w

i

t

h

r

e

s

p

e

c

t

t

o

t

h

e

c

o

r

r

e

c

t

n

e

s

s

o

f

i

n

f

o

r

m

a

t

i

n

i

n

o

t

d

s

i

h

o

c

u

m

e

n

t

.

C

o

p

y

r

i

g

h

t

b

y

V

o

kl

s

w

a

g

e

A

n

.G

10 Rep. Gr.00 - Technical data

Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003

Brake systems - Edition 05.2008

45 –

Anti-lock brake system

1

Generalonotesonanti-lockbraken

sys

o

G.

V

lksw

ag

g

n

A

en

A

G

d

o

a

e

w

s

s

temr

V

lk

ot

g

y

u

nt

b

d

a

e

r

is

a

e

o

th

e

The ABS brakes

system is divided diagonally. The servo-assis

c

u

o

r

a

a

p

tance is effectedl

pneumatically by the vacuum brake servo unit.

s

c

n

e

u

t

Vehiclesi

d

a

a

withABSarenotfittedwithamechanicalbrakepressure

t

e

n

l

t

y

m

i

i

regulator.Speciallymatchedsoftwareinthecontrolunitregulates

r

i

e

force distribution on the rear axle.

b

t

the braket

w

p

l

o

y

n

in the ABS do not influence the brake system and servo

i

Faults,

e

s

t

i

r

h

e

The conventional brake system remains functional

s

assistance.o

p

l

h

without ABS. A change in braking behaviour is to be reck

e

evenw

t

onedr

with.AftertheABSwarninglampcomeson,therearwheels

c

t

n

t

i

may lock prematurely during braking!

o

o

h

t

e

r

a

c

p

ABS layout in left-hand drive vehicle.

n

i

,

s

1o - Hydraulic unit and control unit

e

s

p

2p- Brake servo

r

u

l

a

i

c

r

e

m

m

o

c

r

o

e

t

d

a

o

r

v

i

c

p

u

r

m

f

o

e

g

n

n

i

t

p

.

C

y

o

o

C

p

y

.

t

r

h

g

i

The hydraulic unit -2p- and control unit -1- form one component.

g

h

i

t

r

y

b

o

y

V

They can be separated onlyd

when removed. Hydraulic pump -3-

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y

o

kl

b

e

s

w

a

t

unit..G

g

must not be separated from hydraulicP

e

c

et

or

A

n

With ABS/EDL/TCS/ESP - separation is not possible in vehicles

with hydraulic brake servo or hill hold assist.

1. General notes on anti-lock brake system 11

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enAG

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o

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Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003

o

th

u

Brake systems - Edition 05.2008

le

a

s

s

d

u

n

e

t

t

2

Notes for repair workp e

i

on anti-lock

r

m

brake system

sn

o

t

i

,

e

anti-lock brake system,

♦ Before carrying out repair work on theo

l

h

determinethecauseofthefaultaswellasthecontrolunitcode

using “Guided Fault Finding”.

n

r

i

o

t

“Guided Fault Finding” is carried out with the vehicle diagnostic,

r

a

p

testing and information system -VAS,5051- .

n

i

s

♦ Disconnect battery earth strap with ignition switched off.

e

s

o

p

♦ Before carrying out welding work

with an electric welding unit,

l

r

u

p

note General Information; Body Repairs, General Body Re

pairs .

a

e

i

c

r

m

♦ When working with brake fluid, observe the valid, relevant

m

o

safety precautions and notes page 130o .

c

r

e

t

♦ Afterworkforwhichthebrakesystemhadrtobeopened,bleed

a

v

i

the brake system with brake filling and

bleeding equipment -

f

p

r

VAS 5234or -V.A.G 1869- page 130 .

o

i

g

n

y

p

♦ During the final road test, ensure that a controlled.tbrake test

o

C

h

brake

isperformedatleastonce(pulsationsmustbefeltattheyp

g

i

r

pedal).

o

c

ybd

et

c

et

or

♦ Absolutecleanlinessisrequiredwhenworkingontheanti-lock

P

brake system. It is not permitted to use any products which

contain mineral oil, such as oils, greases etc.

♦ Thoroughly clean all unions and the adjacent areas before loosening. Do not use aggressive cleaning agents such as brake cleanser, petrol, thinners or similar.

♦ Place removed parts on a clean surface and cover.

♦ After separating the control unit/hydraulic unit, use the trans port protection for the contact pins.

♦ If repairs cannot be carried out immediately, carefully cover or seal open components. (Use sealing plugs from repair kit

1 H0 698 311 A).

♦ Only use lint-free cloths.

♦ Only unpack replacement parts immediately prior to fitting. ♦ Only use genuine packed parts.

♦ When the system is open, do not work with compressed air and do not move the vehicle.

♦ Makesurenottotouchanycontactsurfacesontheconnector, pressure sensor and control unit as well as the silicone gel by hand or with objects.

♦ During painting operations, the electronic control unit can be exposed to a maximum temperature of 95 °C for only a short period, and to a maximum of 85 °C for longer periods (approx. 2 hours). Ensure that no brake fluid enters connectors.

olk

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a

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i

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y

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kl

s

w

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e

A

n

.G

12 Rep. Gr.45 - Anti-lock brake system

Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003

Brake systems - Edition 05.2008

3Connecting -VAS 5051and select ing functions

Special tools and workshop equipment required

♦Vehiclediagnosis,testingandinformationsystem-VAS5051-

♦Diagnosis cable -VAS 5051/1- or -VAS 5051/3-

Volksw

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A

en

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o

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w

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lk

ot

WARNING

o

db

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gua

y

r

e

s

a

i

n

r

t

o

e

th

you must always secure testing and

e

♦ During a road test,s

c

u

o

r

a

on the back seat.

a

measuring equipmentle

p

s

c

n

e

u

t

d

maybeoperatedonlybyapassengerwhile

a

i

♦ Thesedevicest

t

e

n

l

i

is in motion.

y

a

the vehicler

l

e

m

b

t

p

i

t

i

y

n

o

i

s

w

t

i

connector of diagnosis cable -VAS 5051/1- or -

r

– Connectl

s

,

h

e

e

- to diagnostic connection.

e

VAS 5051/3h

o

p

w

t

n

c

t

i

r

o

o

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3. Connecting VAS 5051 and selecting functions 13

o

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w

s

s

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lk

ot

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V

Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003

y

g

u

b

d

a

e

r

s

a

i

n

Brake systems - Edition 05.2008

t

r

o

e

th

e

o

u

r

a

a

s

c

–

Switchn

s

c

on tester -arrow-.

t

le

e

u

p

d

a

e

n

The testeri

is ready for operation when the selector buttons for the

a

t

l

t

y

m

modes appear on the screen.

i

operatinge

i

r

b

p

l

–

o

t

s

n

Switch on ignition.

i

,

e

Touch

Guided Fault Finding

on screen.

–ho

l

w

r– Select one after another:

n

i

o

Brand

a♦

t

r

p

n

Type

s♦

i

,

e

Model year

p♦

s

o

r

s

a♦

Body version

o

i

u

f

p

i

n

l

f

r

Engine code

o

♦

m

c

r

e

a

m

t

m

–

cConfirm data entered.

n

i

o

o

n

i

r

t

o

Wait until tester has interrogated all control units in vehicle.

s

i

h

t

e

d

a

o

r

–

v

and select function “Function/component selec

u

Presso

i

c

p

Go to

m

f

r

tion”.

i

t

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n

n

p

.

C

y

–

o

gear” on display.

o

Select “Running.t

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y

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g

h

i

i

t

r

–

y

on display.

o

b

Select “Brake systems”oc

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s

w

a

t

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et

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– Select “01 Self-diagnosis capable system …” shown on dis

or

P

A

.G

play.

– Select “Anti-lock brake system …” shown on display.

– Select “Function” shown on display.

Now all possible functions from the anti-lock brake system instal led in the vehicle will be displayed.

– Select desired function on display.

14 Rep. Gr.45 - Anti-lock brake system

Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003

Brake systems - Edition 05.2008

4Electrical/electronic components and fitting locations

o

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4.1

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ABS Mark 70 (ABS/TCS)

g

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w

s

lk

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V

y

b

d

e

is

r

o

th

unit -J104-

1 - ABS controlsa

u

s

location: on the

Fittingn

le

u

tehydraulic unit on right in

t

d

m

i

engine compartment.

r

e

t Do not separate con

o

p

nector before success

s

n

e

fully completing self-di

i

,

l

agnosis. Switch ignition

h

n

o

off before disconnecting

w

connector.

o

i

r

t

Removing and installing

p

r

a

page 28

i

n

does

not

guarant ee

,
s	2 - ABS hydraulic unit -N55-
o
e
s			Fitting location: on right
u
p
r			in engine compartment.
i
p
l
a
c
	The hydraulic unit consists of
r
e
	the components:
	m
	m
	o
	c
	ABS hydraulic pump -
	r
	o	vV64-
	e
	t
	a
		i	Valveblock(includesin
		r
		p
			r
			o	valves)
			let/outleti
			f
			g
			n
			y			pump -
			ABS hydraulicC.
			p
			o				block
			V64andgivalver
			t
			h
				y
			must not be separatedcy
				p
					o		b
			from one another. cetor
								d
								et	P
			Removing and installing
			page 28

3 - Brake pad warning lamp -

K32-

Fitting location: in dash panel insert.

Function: page 23 .

4 - ABS warning lamp -K47-

Fitting location: in dash panel insert.

Function: page 23 .

5 - Traction control system warning lamp -K86-

Fitting location: in dash panel insert.

Function: page 23 .

6 - Brake system warning lamp -K118-

Fitting location: in dash panel insert.

Function: page 23 .

7 - Brake light switch -F- up to week 45/2005

Including brake pedal switch -F47- .

Fitting location: on brake pedal.

Removing, installing and adjusting page 110 .

4. Electrical/electronic components and fitting locations 15

Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003

Brake systems - Edition 05.2008

8 - Brake light switch -F- from week 45/2005

AG.V lkswagen

en

o

A

G

d

g

o

a

e

w

s

Including brake pedal switch -F47- .

V

s

n

ot

lk

y

o

g

u

b

d

a

t

Fitting location: on brake master cylinder.

r

e

is

a

n

r

o

e

th

e

Removing and installing pages138

c

u

o

r

a

a

s

c

9 - TCS button -E256-

le

e

u

n

a

t

p

e

d

n

Fitting location: in centre console.i

a

t

l

t

y

r

m

i

i

10 - Diagnostic connection

e

b

t

t

w

p

l

i

o

y

n

footwell cover.

i

Fitting location: driver sidei

r

t

,

h

e

e

s

l

-G45- / front left speed sensor -G47-

e

11 - Front right speed sensorh

o

p

w

t

Removing and installingr

page 56

c

o

n

t

i

o

t

12 - Wheel bearing housing

h

c

t

e

r

a

o

p

13 - Wheel bearing/hub unit

c

i

r

r

,

e

s

t

e

ABS sensor ring is installed in the wheel bearing.

n

s

o

e

p

s

r

s

14 - Rear right speed sensor -G44- / rear left speed sensor -G46-

i

u

o

p

f

i

n

l

r

Removing and installing (front-wheel drive) page 57

a

f

r

o

c

m

Removing and installing (four-wheel drive) page 58

i

e

a

m

t

m

o

n

o

c

n

15 - Rear axle assembly with stub axle

i

r

t

o

h

t

s

i

a

e

o

16 - Wheel hub with wheel bearing

v

d

i

c

p

r

u

r

m

ABS sensor ring is installed infthe wheel bearing.

o

e

g

n

n

i

t

p

.

C

y

o

o

C

p

y

.

t

r

h

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h

i

i

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or

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P

n

A

.G

16 Rep. Gr.45 - Anti-lock brake system

Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003

Brake systems - Edition 05.2008

4.2ABS Mark 60 (ABS/EDL/TCS/ESP)

1 - ABS control unit -J104-

Fitting location: on the hydraulic unit on right in engine compartment.

Do not separate con nector before success fully completing self-di agnosis. Switch ignition off before disconnecting connector.

Removing and installingpage 36

2 - ABS hydraulic unit -N55-

Fitting location: on right in engine compartment.

The hydraulic unit consists of the components:

ABS hydraulic pump -

V64-

Brake pressure sender -

G201-

Valveblock(includesin

let/outlet valves)

-

ABS hydraulicwagpumpe

.Volks

n

AG

V64and valve block

s

lk

o

V

musti

y

not be separated

b

d

e

s

one another.

fromth

r

u

les

a

Removing and installing

u

s

page 36

d

n

t

t

e

m

i

3 - Brake pad warning lamp -

r

p

e

K32-

t

n

o

Fitting location: in dash

s

e

panel insert.

i

,

l

o

Function: page 23 .

w

h

n

4 - ABS warning lamp -K47-

o

i

r

t

Fitting location: in dash panel insert.

p

r

a

n

Function: page 23 .

s

i

,

e

5 - ESP and TCS warning lamp -K155-

p

s

o

Only vehicles with ABS/EDL/TCS/ESP.

l

r

u

p

Fitting location: in dash panel insert.

r

a

i

c

Function: page 23 .

m

e

m

6 - Brake system warning lamp -K118-

o

o

c

r

Fitting location: in dash panel insert.

v

e

t

a

i

f Function: page 23 .

r

p

r

o

e

g

n

C

n

7 - Brake light switch -F- up to week 45/2005

t

i

y

.

p

o

o

C

p

Including brake pedal switch -F47- .

y

.

r

t

h

g

g

h

i

i

t

r

y

b

p

on brake pedal.

kl

y

Fitting location:y

V

o

c

b

d

e

s

o

w

a

t

c

page.G

g

e

Removing and installingP

110

et

n

or

A

m

u

c

o

d

s

i

h

t

n

i

n

c t

t o

t h e

c o r r e c t n e s s o f i n f o r

oitam

8 - Brake light switch -F- from week 45/2005

Including brake pedal switch -F47- .

Fitting location: on brake master cylinder.

4. Electrical/electronic components and fitting locations 17

Figure for front-wheel drive 18 - Wheel bearing/hub unit Figure for front-wheel drive

ABS sensor ring is installed in the wheel bearing.

17 - Wheel bearing housing

Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003

Brake systems - Edition 05.2008

Removing and installing page 138 9 - TCS and ESP button -E256-

Only vehicles with ABS/EDL/TCS/ESP.

Fitting location: in centre console.

10 - ESP sensor unit -G419-

enAG.V

wagenA

Only vehicles with ABS/EDL/TCS/ESP.

g

olks

G

d

o

a

e

w

s

Fitting location in Touran: behind glove box.

s

n

g

lk

ot

o

V

y

u

b

d

a

e

Fitting location in Golf and Eos: underoright front seat.

r

e

s

a

i

n

th

r

t

e

Combined lateral acceleration senders

-G200- , yaw rate sender -G202- and longitudinal acceleration

u

o

r

a

a

sender -G251-

l

s

c

p

c

n

e

e

u

t

Combined in one housing.

te

d

a

l

n

i

t

y

m

i

a

i

Removing and installing (Touran) page 60

r

i

e

b

t

p

l

Removing and installing (Golf, Eos) page 60 .

t

o

t

y

n

i

w

s

r

i

11 - Diagnostic connection

l

h

s

,

e

e

o

footwell cover.

p

Fitting location: driver sidew

t

h

e

n

c

t

i

12 - Steering angle sender -G85t

-

h

r

o

o

t

r

e

Fitting location: on steering column between steering wheel and steering column switch.

r

a

c

p

o

n

c

Removing and installings page 61

i

r

,

e

	e
	s	-G45- / -G47-
	o
	p
13 - Front right/left speed sensorr
	u
	p
	l
Removing and installing page 56
	a
14 - Wheel bearing housing	i
	c
	r
	e
	m
	m

15 - Wheel bearing/hub unit	o
	c

	r
	o
ABS sensor ring is installedein the wheel bearing.
	t
	a
	v
	i
	r
	p
16 - Rear right/left speed sensor -G44- / -G46-
	r
	o
Figure for front-wheel drive	f
	g
	n
	i
	y
	p
	o	page 57
	C
Removing and installing (front-wheel.drive)th
	g
	i
	r
	y		page 58
	p
Removing and installing (four-wheel drive)oc
		y
			b
			d
			et
			c
				et
				or
				P

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											n
											t
										.
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i

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t n e s s o f i n f o r

oitam

18 Rep. Gr.45 - Anti-lock brake system

Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003

Brake systems - Edition 05.2008

4.3ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 22/2008

1 - ABS control unit -J104-

Fitting location: on the

hydraulic unit on right in

engine compartment.

Do not separate con

nector before success

fully completing self-di

agnosis. Switch ignition

off before disconnectings

a

connector.

n

s

u

le

d

Removing and installingitt

e

page 42

p

e

r

m

t

2 - ABS hydraulic unitn-N55-

s

o

i

on right

Fitting location:l

,

e

in engine compartment.h

o

w

n

of

The hydraulic unit consistsr

i

the components:

o

r

t

a

p

ABS hydraulic pump -

n

V64-

i

e

,

s

s

Brake pressure sender -

o

G201-

p

l

r

u

p

Valveblock(includesin

a

i

c

let/outlet valves)

r

e

m

ABS hydraulic pump -

m

o

V64and valve

block

e

c

r

o

must not be separatedv

t

a

from one another.

p

i

r

r

Removing and installing

o

f

g

page 42

n

p

i

y

3 - Brake pad warning lamp -

K32-

Fitting location: in dash panel insert.

Function: page 23 .

4 - ABS warning lamp -K47-

Fitting location: in dash panel insert.

Function: page 23 .

5 - ESP and TCS warning lamp -K155-

Only vehicles with ABS/EDL/TCS/ESP.

Fitting location: in dash panel insert.

Function: page 23 .

6 - Brake system warning lamp -K118-

Fitting location: in dash panel insert.

Function: page 23 .

7 - Brake light switch -F- up to week 45/2005

Including brake pedal switch -F47- .

Fitting location: on brake pedal.

Removing and installing page 110

8 - Brake light switch -F- from week 45/2005

Including brake pedal switch -F47- .

Fitting location: on brake master cylinder.

4. Electrical/electronic components and fitting locations 19

Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003

Brake systems - Edition 05.2008

Removing and installing page 138 9 - TCS and ESP button -E256-

Only vehicles with ABS/EDL/TCS/ESP.

Fitting location: in centre console.

10 - ESP sensor unit -G419-

Only vehicles with ABS/EDL/TCS/ESP.

Fitting location in Touran: behind glove box.

Fitting location in Golf and Eos: under right front seat.

Combined lateral acceleration sender -G200- , yaw rate sender -G202- and longitudinal acceleration sender -G251-

Combined in one housing.

Removing and installing (Touran) page 60

Removing and installing (Golf, Eos) page 60 .

11 - Diagnostic connection

Fitting location: driver side footwell cover. 12 - Steering angle sender -G85-

Fitting location: on steering column between steering wheel and steering column switch.

Removing and installing page 61

13 - Front right/left speed sensor -G45- / -G47-Removing and installing page 56

14 - Wheel bearing housing

15 - Wheel bearing/hub unit

ABS sensor ring is installed in the wheel bearing. 16 - Rear right/left speed sensor -G44- / -G46-

Figure for front-wheel drive

Removing and installing (front-wheel drive) page 57

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Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003

Brake systems - Edition 05.2008

4.4ABS Mark 60 (ABS/EDL/TCS/ESP) from week 22/2008

1 -

Fitting location: on the hydraulic unit on right in engine compartment.

Do not separate con nector before success fully completing self-di agnosis. Switch ignition off before disconnecting connector.

The following components are integrated into the control unit: ♦ Lateral acceleration sender

-G200-

♦ Yaw rate sender -G202-

♦ Longitudinal acceleration sender -G251- (in vehicles with four-wheel drive and hill hold assist)

Removing and installingpage 51

2 - ABS hydraulic unit -N55-

Fitting location: on right in engine compartment.

The hydraulic unit consists of the components:

ABS hydraulic pump - V64-

Brake pressure sender - G201-

Valveblock(includesin let/outlet valves)

ABS hydraulic pump - V64and valve block

must not be separated from one another.

Removing and installing page 51

3 - Brake pad warning lamp -K32-

Fitting location: in dash panel insert.

Function: page 23 .

4 - ABS warning lamp -K47-

Fitting location: in dash panel insert.

Function: page 23 .

5 - ESP and TCS warning lamp -K155-

Only vehicles with ABS/EDL/TCS/ESP.

Fitting location: in dash panel insert.

Function: page 23 .

6 - Brake system warning lamp -K118-

Fitting location: in dash panel insert.

Function: page 23 .

7 - Brake light switch -F-

Including brake pedal switch -F47- .

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4. Electrical/electronic components and fitting locations 21

Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003

Brake systems - Edition 05.2008

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ABS sensor ring is installed in the wheel bearing.

22 Rep. Gr.45 - Anti-lock brake system

Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003

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5. Fault display via warning lamps 23

Brake pad warning lamp -K32-

♦ If the brake pad warning lamp -K32- -2- does not go out 3 sec onds after the ignition is switched on, or it comes on during vehicle operation, the fault may be:

-a- The brake pads are worn.

Check brake pads/linings on front and rear axles. Renew worn brake pads/linings.

-b-Thereisawiringfault. Currentflowdiagrams,Electricalfault finding and Fitting locations

ABS warning lamp -K47-

♦ IftheABSwarninglamp-K47--3-doesnotgooutafterswitch ing ignition on and completion of test sequence then the fault may be:

-a- The voltage supply is below 10 volts. -b- There is a fault in the ABS.

Eos 2006 , Golf 2004 , Golf Plus 2005 , Touran 2003 Brake systems - Edition 05.2008

Warning lamps, Golf

Item	Description
1	Traction control system warning lamp -K86-
	ESP and TCS warning lamp -K155-
2	Brake pad warning lamp -K32-
3	ABS warning lamp -K47-
4	Brake system warning lamp -K118-

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♦IftheABSwarninglamp-K47- -3-andthebrakesystemwarn ing lamp -K118- -4- light up, then the ABS is defective. A change in braking behaviour is to be reckoned with.

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24 Rep. Gr.45 - Anti-lock brake system