Volkswagen Eos 2006 User Manual

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Service

Workshop Manual

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

Brake systems

Edition 05.2008

Service Department. Technical Information

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Service

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

Re pa ir G ro up

00 - Technical data

45 - Anti-lock brake system

46 - Brakes - mechanism

47 - Brakes - hydraulics

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.

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.1 ABS Mark 70 (ABS/TCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.2 ABS Mark 60 (ABS/EDL/TCS/ESP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.3 ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 22/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.4 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 22/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5 Fault display via warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6 Assembly overview - hydraulic unit, brake servo/brake master cylinder . . . . . . . . . . . . . . 26

6.1 ABS Mark 70 (ABS/TCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

6.2 ABS Mark 60 (ABS/EDL/TCS/ESP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6.3 ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 22/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6.4 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 22/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . 49

7 Removing and installing parts of ABS system on front and rear axle . . . . . . . . . . . . . . . . 56

7.1 Removing and installing parts of ABS system on front axle . . . . . . . . . . . . . . . . . . . . . . . . 56

7.2 Removing and installing parts of anti-lock brake system on rear axle (front-wheel drive) . . 57

7.3 Removing and installing parts of anti-lock brake system on rear axle (four-wheel drive) . . 58

8 Removing and installing parts of ESP system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

8.1 Removing and installing ESP sensor unit G419 (Touran) . . . . . . . . . . . . . . . . . . . . . . . . . . 60

8.2 Removing and installing ESP sensor unit G419 (Golf, Eos) . . . . . . . . . . . . . . . . . . . . . . . . 60

8.3 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

8.4 Removing and installing brake servo vacuum sender G483 . . . . . . . . . . . . . . . . . . . . . . . . 62

46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1 Repairing front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

1.1 Repairing front brakes, FS III brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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

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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

1 Repairing front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

1.1 Repairing brake caliper FS III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

1.2 Removing and installing piston for brake caliper FS III . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

1.3 Repairing brake caliper FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

1.4 Removing and installing piston for brake caliper FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

1.5 Repairing FNR-G brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

1.6 Removing and installing piston for FNR-G brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . 120

2 Repairing rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

2.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

2.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

2.3 Pre-bleeding brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

3 Pressurised leak test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

3.1 Test prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

4 Bleeding brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

4.1 Bleeding brake system using brake filling and bleeding equipment VAS 5234 or V.A.G 1869

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4.2 Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

5 Brake servo and master brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

5.1 Assembly overview - brake servo/brake master cylinder (left-hand drive vehicle) . . . . . . . . 133

5.2 Assembly overview - brake servo/brake master cylinder (right-hand drive vehicle) . . . . . . 134

5.3 Overview - exhauster pump for brake servo (diesel vehicles) . . . . . . . . . . . . . . . . . . . . . . 136

5.4 Checking non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

5.5 Removing and installing brake servo pressure sensor G294 . . . . . . . . . . . . . . . . . . . . . . 137

5.6 Vacuum pump for brakes V192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

5.7 Removing and installing brake light switch F as of week 45/05 . . . . . . . . . . . . . . . . . . . . . . 138

6 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

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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

Contents iii

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

iv Contents

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

00 – Technical data

1 Brake 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.

Brake systems - Edition 05.2008

1.1 Front brakes, Touran

Engine PR No. Front brake

1.6 l - 75 kW 1ZE FN3 (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

1.9 l - 74, 77 kW TDI

2.0 l - 100, 103 kW TDI

1.4 l -125 kW FSI 1LJ FN3 (16”)

2.0 l - 125 kW TDI

Country-specific brake for Japan:

Engine PR No. Front brake

1.6 l - 85 kW FSI 1ZP FN3 (15”)

2.0 l -110 kW

1.2 Front brakes, Golf

Engine PR No. Front brake

1.4 l - 55, 59 kW

1ZF1) / 1ZM

1.4 l -66 kW FSI

1.6 l - 75 kW

1.6 l - 85 kW FSI

2)

2.0 l - 85 kW

1.9 l - 66 kW TDI

FS III (15”)

1. Brake allocation via PR No. 1

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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 FSI

4)

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

1ZE FN3 (15”)

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.

4)

Golf Plus

5)

with Direct Shift Gearbox 02E - 6-speed or four-wheel drive.

Country specific brake for North America / Japan:

Engine PR No. Front brake

1.6 l -75 kW 1ZP FN3 (15”)

1.6 l - 85 kW FSI

2.0 l -110 kW

2.5 l -110 kW

1.9 l - 74 kW TDI

2.0 l -147 kW FSI 1ZD / 1LV FN3 (16”)

1.3 Front brakes, Eos

Engine PR No. Front brake

1.6 l - 85 kW FSI 1ZE FN3 (15”)

2.0 l -110 kW FSI

2.0 l -147 kW FSI 1LJ FN3 (16”)

2.0 l - 100, 103 kW TDI

3.2 l -184 kW

Country specific brake for North America / Japan:

Engine PR No. Front brake

2.0 l -147 kW FSI 1ZD FN3 (16”)

3.2 l -184 kW

1.4 Rear 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

2 Rep. Gr.00 - Technical data

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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

2.0 l - 125 kW TDI

1)

Gradual switch to 1KF from the end of 2006

1)

1KJ

CII 41 (16”)

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

1.5 Rear 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

1.6 l - 75 kW

1.6 l - 85 kW FSI

2.0 l - 85 kW

1.4 l - 88, 90 kW FSI

1.4 l - 103, 110 kW FSI

2.0 l -110 kW FSI

2.0 l - 55 kW SDI

1.9 l - 66 kW TDI

1.9 l - 77 kW TDI

2.0 l - 100, 103 kW TDI

2.0 l - 147 kW FSI 1KY CII 38 (16”)

1.4 l - 125 kW FSI

2.0 l - 125 kW TDI

1)

Gradual switch to 1KD from the end of 2006

Golf Variant only:

Engine PR No. Rear brake

1.6 l - 75 kW 1KF CII 41 (15”)

1.6 l - 85 kW FSI

2.0 l - 110 kW FSI

1.9 l - 74, 77 kW TDI

2.0 l - 100, 103 kW TDI

1)

1KZ

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

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

2.0 l - 147 kW FSI 1KV CII 38 (16”)

1.6 Rear 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. Rear brake

2.0 l - 110 kW 1KE CII 41 (15”)

1.7 Rear brakes, Eos

Engine PR No. Rear brake

1.6 l - 85 kW FSI 1KD CI 38 (15”)

2.0 l - 110 kW FSI

2.0 l - 100, 103 kW TDI

2.0 l - 147 kW FSI 1KZ CII 38 (16”)

3.2 l - 184 kW

Country specific brake for North America / Japan:

Engine PR No. Rear brake

2.0 l - 147 kW FSI 1KJ CII 41 (16”)

3.2 l - 184 kW

4 Rep. Gr.00 - Technical data

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

2 Technical 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

2.3 Front brakes

2.3.1 Front brakes FS III

Brake systems - Edition 05.2008

Item PR No.

1ZF / 1ZM

1 Brake caliper FS III (15”) 2 Brake pad,

mm 14

thickness Brake pad, wear

mm 2 limit without back plate

3 Brake disc ∅ in

Brake disc, thickness

Brake disc, wear limit

4 Brake caliper

piston

mm

mm 22

mm 19

∅ in

mm

280

54

2. Technical data for brakes 5

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.

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

2.3.2 Front brakes FN 3

Item PR No.

1 Brake caliper FN3 (15”) 2 Brake pad,

thickness Brake pad, wear

limit without back plate

3 Brake disc ∅ in

Brake disc, thickness

Brake disc, wear limit

4 Brake caliper

piston

Item PR No.

1 Brake caliper FN3 (16”) 2 Brake pad,

thickness Brake pad, wear

mm 14

mm 2

mm mm 25

mm 22

∅ in

mm

mm 14

mm 2

1LJ / 1LL / 1ZD / 1LV

limit without

1ZE / 1ZP

back plate

3 Brake disc ∅ in

mm

Brake disc,

mm 25

thickness Brake disc,

mm 22

wear limit

4 Brake caliper

piston

∅ in

mm

288

54

312

54

2.3.3 Front brakes FNR-G

Item PR No.

1 Brake caliper FNR-G (17”) 2 Brake pad,

thickness Brake pad, wear

limit without back plate

3 Brake disc ∅ in

Brake disc, thickness

Brake disc, wear limit

4 Brake caliper

piston

1LK / 1LM

mm 14

mm 2

mm mm 30

mm 27

∅ in

mm

345

57

6 Rep. Gr.00 - Technical data

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2.4 Rear brakes (disc brakes)

2.4.1 Rear brakes CI 38

Item PR No.

1 Brake caliper CI 38 (15”) 2 Brake pad,

3 Brake disc ∅ in

4 Brake caliper

2.4.2 Rear brakes CII 38

Item PR No.

1 Brake caliper CII 38 (16") 2 Brake pad,

thickness Brake pad, wear

limit without back plate

Brake disc, thickness

Brake disc, wear limit

piston

thickness Brake pad, wear

limit without back plate

3 Brake disc ∅ in

Brake disc, thickness

Brake disc, wear limit

4 Brake caliper

piston

mm 11

mm 2

mm

mm 10

mm 8

∅ in

mm

mm 11

mm

mm 12

∅ in

mm

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

Brake systems - Edition 05.2008

1KQ / 1KD

255

38

1KY / 1KZ / 1KV

286

2

10

38

2. Technical data for brakes 7

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

2.4.3 Rear 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

piston

Item PR No.

∅ in

mm

41

1KJ

1 Brake caliper CII 41 (16") 2 Brake pad,

mm 11 thickness

Brake pad, wear limit without back plate

3 Brake disc ∅ in

Brake disc, thickness

Brake disc, wear limit

4 Brake caliper

piston

Item PR No.

1 Brake caliper CII 41 (17") 2 Brake pad,

thickness Brake pad, wear

limit without back plate

3 Brake disc ∅ in

Brake disc, thickness

Brake disc, wear limit

4 Brake caliper

piston

mm 2

mm

mm 12

mm 10

∅ in

mm

mm 11

mm 2

mm

mm 22

mm 20

∅ in

mm

2EL / 2EA

286

41

310

41

8 Rep. Gr.00 - Technical data

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.

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

3 Brake test

3.1 General

♦ 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 ignition is off.

3.2 Test for vehicles with front-wheel drive

The brake test must be performed on a single-axle roller dyna‐ mometer.

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

The test rigs authorised by Volkswagen fulfil these requirements.

3.3 Test for vehicles with four-wheel drive

3.3.1 The brake test should be performed on

Contra-rotating means that the dynamometer rollers are driven

via a Haldex coupling

a single-axle roller dynamometer with contra-rotating rollers for four-wheel drive vehicles.

forwards on one side and backwards on the opposite side.

This prevents brake forces being transferred to the drive train.

The forward rotating wheel is measured during the test, which means two brake tests per axle must be performed.

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

The test rigs authorised by Volkswagen fulfil these requirements.

3.3.2 If no test rig is available for four-wheel drive vehicles, the brake test can also be carried out on a standard single-axle roller dynamometer as follows:

Brake systems - Edition 05.2008

– 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

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.

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.

10 Rep. Gr.00 - Technical data

P

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.

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

45 – Anti-lock brake system

1 General notes on anti-lock brake sys‐

tem

The ABS brake system is divided diagonally. The servo-assis‐ tance is effected pneumatically by the vacuum brake servo unit.

Vehicles with ABS are not fitted with a mechanical brake pressure regulator. Specially matched software in the control unit regulates the brake force distribution on the rear axle.

Faults in the ABS do not influence the brake system and servo assistance. The conventional brake system remains functional even without ABS. A change in braking behaviour is to be reck‐ oned with. After the ABS warning lamp comes on, the rear wheels may lock prematurely during braking!

ABS layout in left-hand drive vehicle.

1 - Hydraulic unit and control unit

2 - Brake servo

The hydraulic unit -2- and control unit -1- form one component. They can be separated only when removed. Hydraulic pump -3must not be separated from hydraulic unit.

With ABS/EDL/TCS/ESP - separation is not possible in vehicles with hydraulic brake servo or hill hold assist.

Brake systems - Edition 05.2008

1. General notes on anti-lock brake system 11

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.

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

2 Notes for repair work on anti-lock

brake system

♦ Before carrying out repair work on the anti-lock brake system,

determine the cause of the fault as well as the control unit code using “Guided Fault Finding”.

“Guided Fault Finding” is carried out with the vehicle diagnostic, testing and information system -VAS 5051- .

♦ Disconnect battery earth strap with ignition switched off.

♦ Before carrying out welding work with an electric welding unit,

note ⇒ General Information; Body Repairs, General Body Re‐ pairs .

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

safety precautions and notes ⇒ page 130 .

♦ After work for which the brake system had to be opened, bleed

the brake system with brake filling and bleeding equipment VAS 5234- or -V.A.G 1869- ⇒ page 130 .

♦ During the final road test, ensure that a controlled brake test

is performed at least once (pulsations must be felt at the brake pedal).

♦ Absolute cleanliness is required when working on the anti-lock

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.

♦ Make sure not to touch any contact surfaces on the connector,

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.

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

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

3 Connecting -VAS 5051- and select‐

ing functions

Special tools and workshop equipment required

♦ Vehicle diagnosis, testing and information system -VAS 5051-

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

WARNING

♦ During a road test, you must always secure testing and

measuring equipment on the back seat.

♦ These devices may be operated only by a passenger while

the vehicle is in motion.

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

VAS 5051/3- to diagnostic connection.

Brake systems - Edition 05.2008

3. Connecting VAS 5051 and selecting functions 13

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

– Switch on tester -arrow-.

The tester is ready for operation when the selector buttons for the operating modes appear on the screen.

– Switch on ignition. – Touch Guided Fault Finding on screen.

– Select one after another:

♦ Brand

♦ Type

♦ Model year

♦ Body version

♦ Engine code

– Confirm data entered.

Wait until tester has interrogated all control units in vehicle. – Press Go to and select function “Function/component selec‐

tion”.

– Select “Running gear” on display.

– Select “Brake systems” on display.

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

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

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

4 Electrical/electronic components and

fitting locations

4.1 ABS Mark 70 (ABS/TCS)

1 - ABS control unit -J104-

❑ Fitting location: on the

❑ Do not separate con‐

❑ Removing and installing

2 - ABS hydraulic unit -N55-

❑ Fitting location: on right

The hydraulic unit consists of the components:

❑ ABS hydraulic pump -

❑ Valve block (includes in‐

❑ ABS hydraulic pump -

hydraulic unit on right in engine compartment.

nector before success‐ fully completing self-di‐ agnosis. Switch ignition off before disconnecting connector.

⇒ page 28

in engine compartment.

V64-

let/outlet valves)

V64- and valve block must not be separated from one another.

❑ 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 .

Brake systems - Edition 05.2008

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

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

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

❑ Including brake pedal switch -F47- . ❑ Fitting location: on brake master cylinder. ❑ Removing and installing ⇒ page 138

9 - TCS button -E256-

❑ Fitting location: in centre console.

10 - Diagnostic connection

❑ Fitting location: driver side footwell cover.

11 - Front right speed sensor -G45- / front left speed sensor -G47-

❑ Removing and installing ⇒ page 56

12 - Wheel bearing housing

13 - Wheel bearing/hub unit

❑ ABS sensor ring is installed in the wheel bearing.

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

❑ Removing and installing (front-wheel drive) ⇒ page 57 ❑ Removing and installing (four-wheel drive) ⇒ page 58

15 - Rear axle assembly with stub axle

16 - Wheel hub with wheel bearing

❑ ABS sensor ring is installed in the wheel bearing.

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

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

4.2 ABS 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 installing

⇒ page 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-

❑ Valve block (includes in‐

let/outlet valves)

❑ ABS hydraulic pump -

V64- and valve block must not be separated from one another.

❑ Removing and installing

⇒ page 36

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.

Brake systems - Edition 05.2008

4. Electrical/electronic components and fitting locations 17

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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 ❑ Removing and installing (four-wheel drive) ⇒ page 58

17 - Wheel bearing housing

Figure for front-wheel drive

18 - Wheel bearing/hub unit

Figure for front-wheel drive

❑ ABS sensor ring is installed in the wheel bearing.

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

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

Brake systems - Edition 05.2008

4.3 ABS 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 disconnecting connector.

❑ Removing and installing

⇒ page 42

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-

❑ Valve block (includes in‐

let/outlet valves)

❑ ABS hydraulic pump -

V64- and valve block must not be separated from one another.

❑ Removing and installing

⇒ page 42

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

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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 ❑ Removing and installing (four-wheel drive) ⇒ page 58

17 - Wheel bearing housing

Figure for front-wheel drive

18 - Wheel bearing/hub unit

Figure for front-wheel drive

❑ ABS sensor ring is installed in the wheel bearing.

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

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

Brake systems - Edition 05.2008

4.4 ABS 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 installing

⇒ page 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-

❑ Valve block (includes in‐

let/outlet valves)

❑ ABS hydraulic pump -

V64- and 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- .

4. Electrical/electronic components and fitting locations 21

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

❑ Fitting location: on brake master cylinder. ❑ Removing and installing ⇒ page 138

8 - TCS and ESP button -E256-

❑ Only vehicles with ABS/EDL/TCS/ESP. ❑ Fitting location: in centre console.

9 - Diagnostic connection

❑ Fitting location: driver side footwell cover.

10 - Steering angle sender -G85-

Note

❑ Fitting location A: on steering column between steering wheel and steering column switch. ❑ Removing and installing ⇒ page 61 ❑ Fitting location B: in steering box.

11 - Front right/left speed sensor -G45- / -G47-

❑ Removing and installing ⇒ page 56

12 - Wheel bearing/hub unit

❑ ABS sensor ring is installed in the wheel bearing.

13 - Rear right/left speed sensor -G44- / -G46-

Figure for front-wheel drive

❑ Removing and installing (front-wheel drive) ⇒ page 57 ❑ Removing and installing (four-wheel drive) ⇒ page 58

14 - Wheel bearing/hub unit

Figure for front-wheel drive

❑ ABS sensor ring is installed in the wheel bearing.

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

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

5 Fault display via warning lamps

Warning lamps, Touran

Brake systems - Edition 05.2008

5. Fault display via warning lamps 23

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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 -K1552 Brake pad warning lamp -K323 ABS warning lamp -K474 Brake system warning lamp -K118-

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- There is a wiring fault. ⇒ Current flow diagrams, Electrical fault finding and Fitting locations

ABS warning lamp -K47-

♦ If the ABS warning lamp -K47- -3- does not go out after switch‐

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.

WARNING

In the event of an ABS fault -b-, the anti-lock brake system remains switched off, but the brake system remains fully op‐ erational.

-c- A temporary speed sensor fault occurred since the vehicle was last started.

In this case, the ABS warning lamp will go out automatically after the engine is restarted and the vehicle speed exceeds 20 km/h.

-d- The connection from dash panel insert to ABS control unit J104- is interrupted. ⇒ Current flow diagrams, Electrical fault finding and Fitting locations

-e- The dash panel insert is defective.

ABS warning lamp -K47- and brake system warning lamp -K118-

♦ If the ABS warning lamp -K47- -3- goes out but the brake sys‐

tem warning lamp -K118- -4- remains on, then the fault may be:

-a- The handbrake is applied.

-b- The brake fluid level is too low (the warning lamp flashes).

Three warning tones are audible after ignition is switched on.

-c- There is a fault in the wiring to brake system warning lamp K118- . ⇒ Current flow diagrams, Electrical fault finding and Fitting locations

♦ If the ABS warning lamp -K47- -3- and the brake system warn‐

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

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

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

WARNING

After the ABS warning lamp -K47- and the brake system warn‐ ing lamp -K118- have lit up, it is possible that the rear wheels will lock up earlier.

Traction control system warning lamp -K86-

♦ If the traction control system warning lamp -K86- -1- does not

go out after switching ignition on and completion of test se‐ quence then the fault may be:

There is a fault present which only affects the TCS. The ABS and EBD safety systems on the vehicle remain fully functional ⇒ In‐ terrogate fault memory.

-a- Short-circuit to positive in TCS button -E256- .

-b- There is a fault in the activation of the traction control system warning lamp -K86- ⇒ Current flow diagrams, Electrical fault find‐ ing and Fitting locations.

-c- The TSC system was shut off by the TCS button -E256- .

If traction control system warning lamp -K86- flashes while the vehicle is in motion, the TCS is regulating the system.

♦ If the TCS warning lamp -K86- -1- does not light up during the

self-test, the fault may be:

-a- The TCS warning lamp -K86- is defective ⇒ perform electrical check.

ESP and TCS warning lamp -K155-

♦ If the ESP and TCS warning lamp -K155- -1- does not go out

after ignition is switched on and test sequence is completed, then the fault may be:

A fault in the system affecting only the TCS/ESP. The ABS/EDL and EBD safety systems on the vehicle remain fully functional ⇒ Interrogate fault memory.

-a- Short-circuit to positive in TCS and ESP button -E256- .

-b- There is a fault in the activation of the ESP and TCS warning lamp -K155- ⇒ Current flow diagrams, Electrical fault finding and Fitting locations.

-c- The TCS/ESP system was shut off by the TCS and ESP button

-E256- .

If the ESP and TCS warning lamp -K155- flashes while the vehicle is in motion, the TCS or ESP system is regulating the system.

♦ If the ESP and TCS warning lamp -K155- -1- does not light up

during the self-test, the fault may be:

-a- The ESP and TCS warning lamp -K155- is defective ⇒ perform electrical check.

Brake systems - Edition 05.2008

5. Fault display via warning lamps 25

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

6 Assembly overview - hydraulic unit,

brake servo/brake master cylinder

6.1 ABS Mark 70 (ABS/TCS)

1 - ABS control unit -J104-

❑ Removing and installing

⇒ page 28

2 - ABS hydraulic unit -N55-

❑ Removing and installing

⇒ page 28

3 - Brake line

❑ From primary piston cir‐

cuit of brake master cyl‐ inder to hydraulic unit

❑ Identification: union nut

with thread M 10 x 1

4 - Brake line

❑ From secondary piston

circuit of brake master cylinder to hydraulic unit

❑ Identification: union nut

with thread M 12 x 1

5 - Brake line

❑ To front left brake cali‐

per

❑ Identification: union nut

with thread M 12 x 1

6 - Brake line

❑ To front right brake cali‐

per

❑ Identification: union nut

with thread M 10 x 1

7 - Brake line

❑ To rear left brake caliper ❑ Identification: union nut

with thread M 12 x 1

8 - Brake line

❑ To rear right brake caliper ❑ Identification: union nut with thread M 10 x 1

9 - Torx socket head bolt, 5.5 Nm

❑ Use new bolts.

10 - Bracket

11 - Hexagon bolt, 8 Nm

12 - Seal

❑ For brake servo.

13 - Brake servo

❑ On petrol engines, the required vacuum is taken from the intake manifold. ❑ Diesel engines are fitted with an exhauster to create the required vacuum ⇒ page 136 .

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

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

Brake systems - Edition 05.2008

❑ Functional check:

– With engine switched off, depress brake pedal firmly several times. (This will release the vacuum in the

unit.)

– Now step on and hold brake pedal with medium pressure and start engine. If the brake servo is functioning

properly, the brake pedal will be felt to go down as the servo takes effect.

❑ If faulty renew complete (check all vacuum lines first). ❑ Removing and installing ⇒ page 141

14 - Sealing ring

15 - Brake master cylinder

❑ Allocation ⇒ Electronic Parts Catalogue (ETKA) . ❑ Cannot be repaired. If faulty, renew as a complete unit. ❑ Removing and installing ⇒ page 139

16 - Hexagon nut, 25 Nm

❑ Always renew after removing

17 - Sealing plug

❑ Moisten with brake fluid and press into brake fluid reservoir.

18 - Brake fluid reservoir

19 - Cap

20 - Sealing plug

❑ Connection for vacuum hose

21 - Vacuum hose

❑ Fit in brake servo

22 - Brake servo pressure sensor -G294-

❑ On vehicles with FSI engine without HBV (Hydraulic Brake with Vacuum servo) ❑ Removing and installing ⇒ page 137

6.1.1 Connecting brake lines from brake mas‐ ter cylinder to hydraulic unit

On brake master cylinder:

A - Primary piston circuit of brake master cylinder to hydraulic unit.

- Identification: union nut with thread M 10 x 1

B - Secondary piston circuit of master brake cylinder to hydraulic unit.

- Identification: union nut with thread M 12 x 1

1 - From hydraulic unit to front left brake caliper.

3 - Hydraulic unit to rear right brake caliper.

4 - Hydraulic unit to rear left brake caliper.

6. Assembly overview - hydraulic unit, brake servo/brake master cylinder 27

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

On hydraulic unit:

A - From hydraulic unit to primary piston circuit of brake master cylinder.

- Identification: union nut with thread M 10 x 1

B - From hydraulic unit to secondary piston circuit of brake master cylinder.

- Identification: union nut with thread M 12 x 1

1 - From hydraulic unit to front left brake caliper.

- Identification: union nut with thread M 12 x 1

2 - From hydraulic unit to front right brake caliper.

- Identification: union nut with thread M 10 x 1

3 - Hydraulic unit to rear right brake caliper.

- Identification: union nut with thread M 10 x 1

4 - Hydraulic unit to rear left brake caliper.

- Identification: union nut with thread M 12 x 1

6.1.2 Removing control unit and hydraulic unit

Special tools and workshop equipment required

♦ Torque wrench -V.A.G

1331-

♦ Torque wrench -V.A.G

1410-

♦ Brake pedal depressor -

V.A.G 1869/2-

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

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

Sealing plugs repair kit, Part No. 1H0 698 311 A

The transport protection for the contact pins must always be placed on the hydraulic unit after the control unit has been dis‐ connected from the hydraulic unit.

No warranty can be assumed for hydraulic units without transport protection.

1 - Transport protection for contact pins (foam)

2 - Sealing plug M 10

3 - Sealing plug M 12

Removing

Fitting location:

The control unit is bolted to the hydraulic unit and is located on right in the engine compartment.

WARNING

Do not bend the brake lines in the area of the hydraulic unit!

– Read out and note the existing control unit code.

– Note or request radio code on vehicles with coded radio if

necessary.

– Disconnect battery ⇒ Electrical system; Rep. Gr. 27 ; Dis‐

connecting and reconnecting battery .

– Remove engine cover panel.

1.4 l TSI engine:

– Remove pressure pipe and intake connecting pipe with regu‐

lating flap control unit ⇒ 4-cylinder injection engine (1.4 l direct injection engine, turbocharger and compressor); Rep. Gr. 24 ; Injection system; Part I - assembly overview - intake manifold .

– Remove charge air hose ⇒ 4-cylinder injection engine (1.4 l

direct injection engine, turbocharger and compressor); Rep. Gr. 21 ; Charge air system .

– Clamp off hose from coolant expansion tank and pull it off.

1.9 l diesel engine:

– Remove connecting hose to intake pipe ⇒ 4-cylinder diesel

engine (2 valve); Rep. Gr. 21 ; Removing and installing charge air system with turbocharger .

– Remove intake manifold flap motor V157 ⇒ 4-cylinder diesel

engine (2 valve); Rep. Gr. 23 ; Removing and installing mix‐ ture preparation - injection .

2.0 l diesel engine:

– Touran vehicles only: remove plenum chamber middle bulk‐

head ⇒ General body repairs, exterior; Rep. Gr. 50 ; Assem‐ bly overview - plenum chamber bulkhead .

– Remove connecting pipe between intake hose and turbo‐

charger.

– Remove toothed belt guard upper part.

Brake systems - Edition 05.2008

6. Assembly overview - hydraulic unit, brake servo/brake master cylinder 29

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

Diesel engines with diesel particulate filter:

– Unscrew exhaust gas pressure sensor 1 -G450- , separate

electrical connectors, unscrew and lower diesel particulate fil‐ ter ⇒ Rep. Gr. 26 ; Assembly overview - front exhaust pipe with particulate filter .

Continuation for all vehicles:

– Release connector on control unit in direction of arrow -1- and

pull off -2-.

– Apply brake pedal depressor -V.A.G 1869/2- .

– Connect bleeder bottle hose to front left brake caliper bleeder

valve and rear left brake caliper bleeder valve and open bleed‐ er valves.

– Depress brake pedal at least 60 mm using brake pedal de‐

pressor -V.A.G 1869/2- .

– Close front left and rear left bleeder valve.

– Do not remove brake pedal depressor -V.A.G 1869/2- .

– Place sufficient lint-free cloths under the control unit and hy‐

draulic unit.

Ensure no brake fluid gets onto contacts.

– First identify the two brake master cylinder brake lines

-A and B- and unscrew from the hydraulic unit.

– Immediately seal brake lines and threaded holes with seal

plugs from repair set Part No. 1H0 698 311 A.

– Identify brake lines (brake calipers) -1 to 4-, unscrew and seal.

– Pull hydraulic unit with control unit upwards out of dampers.

6.1.3 Unbolting control unit from hydraulic unit

– Place hydraulic unit with control unit upwards on a clean flat

level surface.

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

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

– Remove Torx socket head bolts -arrows-.

– Without canting it, pull control unit off from hydraulic unit

-arrow-.

– Carefully pull all seals from hydraulic unit contact pins.

♦ The printed circuit board becomes visible when the control

unit is removed.

♦ No moisture or particles of dirt may enter the control unit.

♦ Hydraulic pump must not be separated from hydraulic unit.

♦ Avoid electrostatic charge!

– Cover control unit solenoids with a lint-free cloth.

After separating control unit and hydraulic unit, use transport pro‐ tection for contact pins.

WARNING

6.1.4 Installing new control unit

Brake systems - Edition 05.2008

WARNING

Severe shocks (e.g. dropping, impact) may destroy the control unit. The control unit must not then be used.

• Clean surfaces before assembling.

– Push all seals -A- over contact pins slightly.

– Without canting it, place control unit onto hydraulic unit.

The seals are thus moved to end position.

– Bolt hydraulic unit and control unit with enclosed, new Torx

socket head bolts.

Note

♦

A new control unit may be mounted on an existing hydraulic unit max. twice to guarantee impermeability of the elastic seal.

♦

A control unit which has already been operated in a vehicle must not be installed a second time.

6. Assembly overview - hydraulic unit, brake servo/brake master cylinder 31

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

6.1.5 Installing control unit and hydraulic unit

Note

♦

Remove sealing plugs from new hydraulic unit only when the corresponding brake line is going to be fitted.

♦

If sealing plugs are removed too early from the hydraulic unit, brake fluid can escape, and it can then no longer be guaran‐ teed that the unit can be sufficiently filled and bled.

♦

When installing, ensure that rubber dampers are not pressed out of bracket.

– Install in reverse order.

– Remove brake pedal depressor -V.A.G 1869/2- .

– Bleed brake system ⇒ page 130 .

– Code radio.

– Code control unit -J104- with ⇒ Vehicle diagnosis, testing and

information system VAS 5051 in ”Guided fault finding”.

Specified torques: Control unit to hydraulic unit

♦ Use new bolts!

Hexagon bolt of hydraulic unit to bracket 8 Nm Brake lines to ABS assembly: Thread M 10 x 1 14 Nm Thread M 12 x 1 14 Nm

5.5 Nm

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

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

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

1 - ABS control unit -J104-

Separation of the control unit and hydraulic unit is not possi‐ ble in vehicles with hydraulic brake servo or hill hold assist.

❑ Removing and installing

⇒ page 36

2 - ABS hydraulic unit -N55-

Separation of the control unit and hydraulic unit is not possi‐ ble in vehicles with hydraulic brake servo or hill hold assist.

❑ Removing and installing

⇒ page 36

3 - Brake line

❑ From primary piston cir‐

cuit of brake master cyl‐ inder to hydraulic unit

❑ Identification: ∅ 6.5 mm

and union nut with long thread M 12x1.

4 - Brake line

❑ From secondary piston

circuit of brake master cylinder to hydraulic unit

❑ Identification: ∅ 6.5 mm

and union nut with long thread M 12x1.

5 - Brake line

❑ To front left brake cali‐

per

❑ Identification: ∅

5.25 mm and union nut with short thread M 12x1.

6 - Brake line

❑ To front right brake caliper ❑ Identification: ∅ 5.25 mm and union nut with thread M 10x1.

7 - Brake line

❑ To rear left brake caliper ❑ Identification: ∅ 5.25 mm and union nut with short thread M 12x1.

8 - Brake line

❑ To rear right brake caliper ❑ Identification: ∅ 5.25 mm and union nut with thread M 10x1.

Brake systems - Edition 05.2008

9 - Torx socket head bolt, 5.5 Nm

❑ Use new bolts.

10 - Bracket

11 - Hexagon bolt, 8 Nm

12 - Seal

❑ For brake servo.

6. Assembly overview - hydraulic unit, brake servo/brake master cylinder 33

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

13 - Brake servo

❑ On petrol engines, the required vacuum is taken from the intake manifold. ❑ Some vehicles with a petrol engine and an automatic gearbox are equipped with a brake vacuum pump

⇒ page 137 .

❑ A vacuum sender is fitted in vehicles with HBV ⇒ page 62 . ❑ Diesel engines are fitted with an exhauster to create the required vacuum ⇒ page 136 . ❑ Functional check:

– With engine switched off, depress brake pedal firmly several times. (This will release the vacuum in the

unit.)

– Now step on and hold brake pedal with medium pressure and start engine. If the brake servo is functioning

properly, the brake pedal will be felt to go down as the servo takes effect.

❑ If faulty renew complete (check all vacuum lines first). ❑ Removing and installing ⇒ page 141

14 - Sealing ring

15 - Brake servo vacuum sender -G483-

❑ Only on vehicles having HBV ❑ Removing and installing ⇒ page 62

16 - Brake master cylinder

❑ Allocation ⇒ Electronic Parts Catalogue (ETKA) . ❑ Cannot be repaired. If faulty, renew as a complete unit. ❑ Removing and installing ⇒ page 139

17 - Heat shield

18 - Hexagon nut, 25 Nm

❑ Always renew after removing

19 - Sealing plug

❑ Moisten with brake fluid and press into brake fluid reservoir.

20 - Brake fluid reservoir

21 - Cap

22 - Sealing plug

❑ Connection for vacuum hose

23 - Vacuum hose

❑ Fit in brake servo

6.2.1 Connecting brake lines from brake mas‐ ter cylinder to hydraulic unit

On brake master cylinder:

A - Primary piston circuit of brake master cylinder to hydraulic unit.

- Identification: ∅ 6.5 mm and union nut with thread M 12x1.

B - Secondary piston circuit of master brake cylinder to hydraulic unit.

- Identification: ∅ 6.5 mm and union nut with thread M 12x1.

1 - From hydraulic unit to front left brake caliper.

3 - Hydraulic unit to rear right brake caliper.

4 - Hydraulic unit to rear left brake caliper.

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

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

On hydraulic unit:

A - From hydraulic unit to primary piston circuit of brake master cylinder.

- Identification: ∅ 6.5 mm and union nut with long thread M 12x1.

B - From hydraulic unit to secondary piston circuit of brake master cylinder.

- Identification: ∅ 6.5 mm and union nut with long thread M 12x1.

1 - From hydraulic unit to front left brake caliper.

- Identification: ∅ 5.25 mm and union nut with short thread M 12x1.

2 - From hydraulic unit to front right brake caliper.

- Identification: ∅ 5.25 mm and union nut with thread M 10x1.

3 - Hydraulic unit to rear right brake caliper.

- Identification: ∅ 5.25 mm and union nut with thread M 10x1.

4 - Hydraulic unit to rear left brake caliper.

- Identification: ∅ 5.25 mm and union nut with short thread M 12x1.

Brake systems - Edition 05.2008

6. Assembly overview - hydraulic unit, brake servo/brake master cylinder 35

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

6.2.2 Removing control unit and hydraulic unit

Special tools and workshop equipment required

♦ Torque wrench -V.A.G

1331-

♦ Torque wrench -V.A.G

1410-

♦ Brake pedal depressor -

V.A.G 1869/2-

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

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

Brake systems - Edition 05.2008

Sealing plugs repair kit, Part No. 1H0 698 311 A

The transport protection for the contact pins must always be placed on the hydraulic unit after the control unit has been dis‐ connected from the hydraulic unit.

No warranty can be assumed for hydraulic units without transport protection.

1 - Transport protection for contact pins (foam)

2 - Sealing plug M 10

3 - Sealing plug M 12

Removing

Fitting location:

The control unit is bolted to the hydraulic unit and is located on right in the engine compartment.

WARNING

Do not bend the brake lines in the area of the hydraulic unit!

– Read out and note the existing control unit code.

– Note or request radio code on vehicles with coded radio if

necessary.

– Disconnect battery ⇒ Electrical system; Rep. Gr. 27 ; Dis‐

connecting and reconnecting battery .

– Remove engine cover panel.

1.4 l TSI engine:

– Remove pressure pipe and intake connecting pipe with regu‐

lating flap control unit ⇒ 4-cylinder injection engine (1.4 l direct injection engine, turbocharger and compressor); Rep. Gr. 24 ; Injection system; Part I - assembly overview - intake manifold .

– Remove charge air hose ⇒ 4-cylinder injection engine (1.4 l

direct injection engine, turbocharger and compressor); Rep. Gr. 21 ; Charge air system .

– Clamp off hose from coolant expansion tank and pull it off.

1.9 l diesel engine:

– Remove connecting hose to intake pipe ⇒ 4-cylinder diesel

engine (2 valve); Rep. Gr. 21 ; Removing and installing charge air system with turbocharger .

– Remove intake manifold flap motor V157 ⇒ 4-cylinder diesel

engine (2 valve); Rep. Gr. 23 ; Removing and installing mix‐ ture preparation - injection .

2.0 l diesel engine:

– Touran vehicles only: remove plenum chamber middle bulk‐

head ⇒ General body repairs, exterior; Rep. Gr. 50 ; Assem‐ bly overview - plenum chamber bulkhead .

– Remove connecting pipe between intake hose and turbo‐

charger.

– Remove toothed belt guard upper part.

6. Assembly overview - hydraulic unit, brake servo/brake master cylinder 37

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

Diesel engines with diesel particulate filter:

– Unscrew exhaust gas pressure sensor 1 -G450- , separate

electrical connectors, unscrew and lower diesel particulate fil‐ ter ⇒ Rep. Gr. 26 ; Assembly overview - front exhaust pipe with particulate filter .

Continuation for all vehicles:

– Release connector on control unit in direction of arrow -1- and

pull off -2-.

– Apply brake pedal depressor -V.A.G 1869/2- .

– Connect bleeder bottle hose to front left brake caliper bleeder

valve and rear left brake caliper bleeder valve and open bleed‐ er valves.

– Depress brake pedal at least 60 mm using brake pedal de‐

pressor -V.A.G 1869/2- .

– Close front left and rear left bleeder valve.

– Do not remove brake pedal depressor -V.A.G 1869/2- .

– Place sufficient lint-free cloths under the control unit and hy‐

draulic unit.

Ensure no brake fluid gets onto contacts.

– First identify the two brake master cylinder brake lines

-A and B- and unscrew from the hydraulic unit.

– Immediately seal brake lines and threaded holes with seal

plugs from repair set Part No. 1H0 698 311 A.

– Identify brake lines (brake calipers) -1 to 4-, unscrew and seal.

– Pull hydraulic unit with control unit upwards out of dampers.

6.2.3 Unbolting control unit from hydraulic unit

Note

Separation of the control unit and hydraulic unit is not possible in vehicles with hydraulic brake servo or hill hold assist.

– Place hydraulic unit with control unit downwards on a clean

flat level surface.

– Remove Torx socket head bolts E5 -arrows- from hydraulic

pump.

WARNING

Hydraulic pump must not be separated from hydraulic unit.

Avoid electrostatic charge!

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

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

– The hydraulic pump must therefore be secured onto the hy‐

draulic unit with the red retainer -1- from the repair kit and two sealing plugs -2-.

– Carefully lift hydraulic unit with hydraulic pump at joint -1- up‐

wards off control unit.

Brake systems - Edition 05.2008

When pulling off the control unit, ensure that the hydraulic unit contact pins are not canted against the control unit solenoids.

Item 2 adapter for pump motor.

– Cover control unit solenoids with a lint-free cloth.

After separating control unit and hydraulic unit, use transport pro‐ tection for contact pins.

6.2.4 Installing new control unit

WARNING

Severe shocks (e.g. dropping, impact) may destroy the control unit. The control unit must not then be used.

♦ Before the new control unit can be installed, the pump motor

adapter must be inserted to stop and must engage. Make sure not to damage the adapter guide.

♦ The adapter supplied as a spare part for the control unit can

only be engaged once and then cannot be removed.

♦ The white paste on the bottom of the control unit serves as

sealant and must not be removed.

♦ Make sure not to touch any contact surfaces on the adapter,

pressure sensor and control unit as well as the silicone gel and the sealing components by hand or with objects to prevent them from being dirty or damaged.

6. Assembly overview - hydraulic unit, brake servo/brake master cylinder 39

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

– Press adapter into adapter guide to stop; it must then be en‐

gaged.

– Without canting it, place control unit onto hydraulic unit.

– Bolt hydraulic unit and control unit with the new Torx bolts

which are enclosed.

Note

♦

A new control unit may be mounted on an existing hydraulic unit max. twice to guarantee impermeability of the elastic seal.

♦

A control unit which has already been operated in a vehicle must not be installed a second time.

6.2.5 Installing control unit and hydraulic unit

Note

♦

Remove sealing plugs from new hydraulic unit only when the corresponding brake line is going to be fitted.

♦

If sealing plugs are removed too early from the hydraulic unit, brake fluid can escape, and it can then no longer be guaran‐ teed that the unit can be sufficiently filled and bled.

– Install in reverse order.

– Remove brake pedal depressor -V.A.G 1869/2- .

– Bleed brake system ⇒ page 130 .

– Code radio.

– Code control unit -J104- with ⇒ Vehicle diagnosis, testing and

information system VAS 5051 in ”Guided fault finding”.

To do this, basic setting of the steering angle sender -G85- , the lateral acceleration sender -G200- and the brake pressure sender

-G201- must be carried out.

Specified torques: Control unit to hydraulic unit

♦ Use new bolts!

Hexagon bolt of hydraulic unit to bracket 8 Nm Brake lines to ABS assembly: Thread M 10 x 1 14 Nm Thread M 12 x 1 14 Nm

5.5 Nm

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

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

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

1 - ABS control unit -J104-

Separation of the control unit and hydraulic unit is not possi‐ ble in vehicles with hydraulic brake servo or hill hold assist.

❑ Removing and installing

⇒ page 42

2 - ABS hydraulic unit -N55-

Separation of the control unit and hydraulic unit is not possi‐ ble in vehicles with hydraulic brake servo or hill hold assist.

❑ Removing and installing

⇒ page 42

3 - Brake line

❑ From primary piston cir‐

cuit of brake master cyl‐ inder to hydraulic unit

❑ Identification: ∅ 6.5 mm

and union nut with long thread M 12x1.

Brake systems - Edition 05.2008

4 - Brake line

❑ From secondary piston

circuit of brake master cylinder to hydraulic unit

❑ Identification: ∅ 6.5 mm

and union nut with long thread M 12x1.

5 - Brake line

❑ To front left brake cali‐

per

❑ Identification: ∅

5.25 mm and union nut with short thread M 12x1.

6 - Brake line

❑ To front right brake caliper ❑ Identification: ∅ 5.25 mm and union nut with thread M 10x1.

7 - Brake line

❑ To rear left brake caliper ❑ Identification: ∅ 5.25 mm and union nut with short thread M 12x1.

8 - Brake line

❑ To rear right brake caliper ❑ Identification: ∅ 5.25 mm and union nut with thread M 10x1.

9 - Torx socket head bolt, 5.5 Nm

❑ Use new bolts.

10 - Retainer

11 - Hexagon bolt, 8 Nm

12 - Seal

❑ For brake servo.

6. Assembly overview - hydraulic unit, brake servo/brake master cylinder 41

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

13 - Brake servo

❑ On petrol engines, the required vacuum is taken from the intake manifold. ❑ Some vehicles with a petrol engine and an automatic gearbox are equipped with a brake vacuum pump

⇒ page 137 .

❑ A vacuum sender is fitted in vehicles with HBV ⇒ page 62 . ❑ Diesel engines are fitted with an exhauster to create the required vacuum ⇒ page 136 . ❑ Functional check:

– With engine switched off, depress brake pedal firmly several times. (This will release the vacuum in the

unit.)

– Now step on and hold brake pedal with medium pressure and start engine. If the brake servo is functioning

properly, the brake pedal will be felt to go down as the servo takes effect.

❑ If faulty renew complete (check all vacuum lines first). ❑ Removing and installing ⇒ page 141

14 - Sealing ring

15 - Brake servo vacuum sender -G483-

❑ Only on vehicles having HBV ❑ Removing and installing ⇒ page 62

16 - Brake master cylinder

❑ Allocation ⇒ Electronic Parts Catalogue (ETKA) . ❑ Cannot be repaired. If faulty, renew as a complete unit. ❑ Removing and installing ⇒ page 139

17 - Heat shield

18 - Hexagon nut, 25 Nm

❑ Always renew after removing

19 - Sealing plug

❑ Moisten with brake fluid and press into brake fluid reservoir.

20 - Brake fluid reservoir

21 - Cap

22 - Sealing plug

❑ Connection for vacuum hose

23 - Vacuum hose

❑ Fit in brake servo

6.3.1 Connecting brake lines from brake mas‐ ter cylinder to hydraulic unit

On brake master cylinder:

A - Primary piston circuit of brake master cylinder to hydraulic unit.

- Identification: ∅ 6.5 mm and union nut with thread M 12x1.

B - Secondary piston circuit of master brake cylinder to hydraulic unit.

- Identification: ∅ 6.5 mm and union nut with thread M 12x1.

1 - From hydraulic unit to front left brake caliper.

3 - Hydraulic unit to rear right brake caliper.

4 - Hydraulic unit to rear left brake caliper.

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

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

Brake systems - Edition 05.2008

On hydraulic unit:

A - From hydraulic unit to primary piston circuit of brake master cylinder.

- Identification: ∅ 6.5 mm and union nut with long thread M 12x1.

B - From hydraulic unit to secondary piston circuit of brake master cylinder.

- Identification: ∅ 6.5 mm and union nut with long thread M 12x1.

1 - From hydraulic unit to front left brake caliper.

- Identification: ∅ 5.25 mm and union nut with short thread M 12x1.

2 - From hydraulic unit to front right brake caliper.

- Identification: ∅ 5.25 mm and union nut with thread M 10x1.

3 - Hydraulic unit to rear right brake caliper.

- Identification: ∅ 5.25 mm and union nut with thread M 10x1.

4 - Hydraulic unit to rear left brake caliper.

- Identification: ∅ 5.25 mm and union nut with short thread M 12x1.

6. Assembly overview - hydraulic unit, brake servo/brake master cylinder 43

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

6.3.2 Removing control unit and hydraulic unit

Special tools and workshop equipment required

♦ Torque wrench -V.A.G

1331-

♦ Torque wrench -V.A.G

1410-

♦ Brake pedal depressor -

V.A.G 1869/2-

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

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

Sealing plugs repair kit, Part No. 1H0 698 311 A

The transport protection for the contact pins must always be placed on the hydraulic unit after the control unit has been dis‐ connected from the hydraulic unit.

No warranty can be assumed for hydraulic units without transport protection.

1 - Transport protection for contact pins (foam)

2 - Sealing plug M 10

3 - Sealing plug M 12

Removing

Fitting location:

The control unit is bolted to the hydraulic unit and is located on right in the engine compartment.

Do not bend the brake lines in the area of the hydraulic unit!

– Read out and note the existing control unit code.

– Note or request radio code on vehicles with coded radio if

necessary.

– Disconnect battery ⇒ Electrical system; Rep. Gr. 27 ; Dis‐

connecting and reconnecting battery .

– Remove engine cover panel.

1.4 l TSI engine:

WARNING

– Remove pressure pipe and intake connecting pipe with regu‐

lating flap control unit ⇒ 4-cylinder injection engine (1.4 l direct injection engine, turbocharger and compressor); Rep. Gr. 24 ; Injection system; Part I - assembly overview - intake manifold .

Brake systems - Edition 05.2008

– Remove charge air hose ⇒ 4-cylinder injection engine (1.4 l

direct injection engine, turbocharger and compressor); Rep. Gr. 21 ; Charge air system .

– Clamp off hose from coolant expansion tank and pull it off.

1.9 l diesel engine:

– Remove connecting hose to intake pipe ⇒ 4-cylinder diesel

engine (2 valve); Rep. Gr. 21 ; Removing and installing charge air system with turbocharger .

– Remove intake manifold flap motor V157 ⇒ 4-cylinder diesel

engine (2 valve); Rep. Gr. 23 ; Removing and installing mix‐ ture preparation - injection .

2.0 l diesel engine:

– Touran vehicles only: remove plenum chamber middle bulk‐

head ⇒ General body repairs, exterior; Rep. Gr. 50 ; Assem‐ bly overview - plenum chamber bulkhead .

– Remove connecting pipe between intake hose and turbo‐

charger.

– Remove toothed belt guard upper part.

6. Assembly overview - hydraulic unit, brake servo/brake master cylinder 45

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

Diesel engines with diesel particulate filter:

– Unscrew exhaust gas pressure sensor 1 -G450- , separate

electrical connectors, unscrew and lower diesel particulate fil‐ ter ⇒ Rep. Gr. 26 ; Assembly overview - front exhaust pipe with particulate filter .

Continuation for all vehicles:

– Release connector on control unit in direction of arrow -1- and

pull off -2-.

– Apply brake pedal depressor -V.A.G 1869/2- .

– Connect bleeder bottle hose to front left brake caliper bleeder

valve and rear left brake caliper bleeder valve and open bleed‐ er valves.

– Depress brake pedal at least 60 mm using brake pedal de‐

pressor -V.A.G 1869/2- .

– Close front left and rear left bleeder valve.

– Do not remove brake pedal depressor -V.A.G 1869/2- .

– Place sufficient lint-free cloths under the control unit and hy‐

draulic unit.

Ensure no brake fluid gets onto contacts.

– First identify the two brake master cylinder brake lines

-A and B- and unscrew from the hydraulic unit.

– Immediately seal brake lines and threaded holes with seal

plugs from repair set Part No. 1H0 698 311 A.

– Identify brake lines (brake calipers) -1 to 4-, unscrew and seal.

– Pull hydraulic unit with control unit upwards out of dampers.

6.3.3 Unbolting control unit from hydraulic unit

Note

Separation of the control unit and hydraulic unit is not possible in vehicles with hydraulic brake servo or hill hold assist.

– Place hydraulic unit with control unit downwards on a clean

flat level surface.

– Remove Torx socket head bolts E5 -arrows- from hydraulic

pump.

WARNING

Hydraulic pump must not be separated from hydraulic unit.

Avoid electrostatic charge!

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

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

– The hydraulic pump must therefore be secured onto the hy‐

draulic unit with the red retainer -1- from the repair kit and two sealing plugs -2-.

– Carefully lift hydraulic unit with hydraulic pump at joint -1- up‐

wards off control unit.

When pulling off the control unit, ensure that the hydraulic unit contact pins are not canted against the control unit solenoids.

Item 2 adapter for pump motor.

– Cover control unit solenoids with a lint-free cloth.

After separating control unit and hydraulic unit, use transport pro‐ tection for contact pins.

Brake systems - Edition 05.2008

6.3.4 Installing new control unit

WARNING

Severe shocks (e.g. dropping, impact) may destroy the control unit. The control unit must not then be used.

♦ Before the new control unit can be installed, the pump motor

adapter must be inserted to stop and must engage. Make sure not to damage the adapter guide.

♦ The adapter supplied as a spare part for the control unit can

only be engaged once and then cannot be removed.

♦ The white paste on the bottom of the control unit serves as

sealant and must not be removed.

♦ Make sure not to touch any contact surfaces on the adapter,

pressure sensor and control unit as well as the silicone gel and the sealing components by hand or with objects to prevent them from being dirty or damaged.

6. Assembly overview - hydraulic unit, brake servo/brake master cylinder 47

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

– Press adapter into adapter guide to stop; it must then be en‐

gaged.

– Without canting it, place control unit onto hydraulic unit.

– Bolt hydraulic unit and control unit with the new Torx bolts

which are enclosed.

Note

♦

A new control unit may be mounted on an existing hydraulic unit max. twice to guarantee impermeability of the elastic seal.

♦

A control unit which has already been operated in a vehicle must not be installed a second time.

6.3.5 Installing control unit and hydraulic unit

Note

♦

Remove sealing plugs from new hydraulic unit only when the corresponding brake line is going to be fitted.

♦

If sealing plugs are removed too early from the hydraulic unit, brake fluid can escape, and it can then no longer be guaran‐ teed that the unit can be sufficiently filled and bled.

– Install in reverse order.

– Remove brake pedal depressor -V.A.G 1869/2- .

– Bleed brake system ⇒ page 130 .

– Code radio.

– Code control unit -J104- with ⇒ Vehicle diagnosis, testing and

information system VAS 5051 in ”Guided fault finding”.

To do this, basic setting of the steering angle sender -G85- , the lateral acceleration sender -G200- and the brake pressure sender

-G201- must be carried out.

Specified torques: Control unit to hydraulic unit

5.5 Nm

♦ Use new bolts!

Hexagon bolt of hydraulic unit to bracket 8 Nm Brake lines to ABS assembly: Thread M 10 x 1 14 Nm Thread M 12 x 1 14 Nm

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

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

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

1 - ABS control unit -J104-

❑ Removing and installing

⇒ page 51

2 - Torx socket head bolt, 2 Nm + 0.8 Nm

❑ Use new bolts.

3 - ABS hydraulic unit -N55-

❑ Removing and installing

⇒ page 51

4 - Brake line

❑ From primary piston cir‐

cuit of brake master cyl‐ inder to hydraulic unit

❑ Identification: ∅ 6.5 mm

and union nut with thread M 12x1.

5 - Brake line

❑ From secondary piston

circuit of brake master cylinder to hydraulic unit

❑ Identification: ∅ 6.5 mm

Brake systems - Edition 05.2008

and union nut with thread M 12x1.

6 - Brake line

❑ To front left brake cali‐

per

❑ Identification: ∅

5.25 mm and union nut with thread M 10x1.

7 - Brake line

❑ To front right brake cali‐

per

❑ Identification: ∅ 5.25

mm and union nut with thread M 12x1.

8 - Brake line

❑ To rear left brake caliper ❑ Identification: ∅ 5.25 mm and union nut with thread M 12x1.

9 - Brake line

❑ To rear right brake caliper ❑ Identification: ∅ 5.25 mm and union nut with thread M 10x1.

10 - Brake servo

❑ See ⇒ page 133 . ❑ Removing and installing ⇒ page 141

11 - Retainer

❑ Check for secure seating after installing.

6. Assembly overview - hydraulic unit, brake servo/brake master cylinder 49

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

12 - Torx bolt, 8 Nm

13 - Rubber damper

14 - Hexagon fitted bolt, 8 Nm

15 - Bracket

16 - Rubber damper

❑ Ensure that rubber dampers of retainer are not pressed out of bracket when installing.

17 - Hexagon nut, 20 Nm

18 - Heat shield

19 - Hexagon nut, 8 Nm

6.4.1 Connecting brake lines from brake mas‐ ter cylinder to hydraulic unit

On brake master cylinder:

A - Primary piston circuit of brake master cylinder to hydraulic unit.

- Identification: ∅ 6.5 mm and union nut with thread M 12x1.

B - Secondary piston circuit of master brake cylinder to hydraulic unit.

- Identification: ∅ 6.5 mm and union nut with thread M 12x1.

1 - From hydraulic unit to front left brake caliper.

3 - Hydraulic unit to rear right brake caliper.

4 - Hydraulic unit to rear left brake caliper.

On hydraulic unit:

A - From hydraulic unit to primary piston circuit of brake master cylinder.

- Identification: ∅ 6.5 mm and union nut with thread M 12x1.

B - From hydraulic unit to secondary piston circuit of brake master cylinder.

- Identification: ∅ 6.5 mm and union nut with thread M 12x1.

1 - From hydraulic unit to front left brake caliper.

- Identification: ∅ 5.25 mm and union nut with thread M 10x1.

2 - From hydraulic unit to front right brake caliper.

- Identification: ∅ 5.25 mm and union nut with thread M 12x1.

3 - Hydraulic unit to rear right brake caliper.

- Identification: ∅ 5.25 mm and union nut with thread M 10x1.

4 - Hydraulic unit to rear left brake caliper.

- Identification: ∅ 5.25 mm and union nut with thread M 12x1.

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

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

6.4.2 Removing control unit and hydraulic unit

Special tools and workshop equipment required

♦ Torque wrench -V.A.G

1331-

♦ Torque wrench -V.A.G

1410-

♦ Brake pedal depressor -

V.A.G 1869/2-

Brake systems - Edition 05.2008

6. Assembly overview - hydraulic unit, brake servo/brake master cylinder 51

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

Sealing plugs repair kit, Part No. 1H0 698 311 A

The transport protection for the contact pins must always be placed on the hydraulic unit after the control unit has been dis‐ connected from the hydraulic unit.

No warranty can be assumed for hydraulic units without transport protection.

1 - Transport protection for contact pins (foam)

2 - Sealing plug M 10

3 - Sealing plug M 12

Removing

Fitting location:

The control unit is bolted to the hydraulic unit and is located on right in the engine compartment.

WARNING

Do not bend the brake lines in the area of the hydraulic unit!

– Read out and note the existing control unit code.

– Note or request radio code on vehicles with coded radio if

necessary.

– Disconnect battery ⇒ Electrical system; Rep. Gr. 27 ; Dis‐

connecting and reconnecting battery .

– Remove engine cover panel.

1.4 l TSI engine:

– Remove pressure pipe and intake connecting pipe with regu‐

lating flap control unit ⇒ 4-cylinder injection engine (1.4 l direct injection engine, turbocharger and compressor); Rep. Gr. 24 ; Injection system; Part I - assembly overview - intake manifold .

– Remove charge air hose ⇒ 4-cylinder injection engine (1.4 l

direct injection engine, turbocharger and compressor); Rep. Gr. 21 ; Charge air system .

– Clamp off hose from coolant expansion tank and pull it off.

1.9 l diesel engine:

– Remove connecting hose to intake pipe ⇒ 4-cylinder diesel

engine (2 valve); Rep. Gr. 21 ; Removing and installing charge air system with turbocharger .

– Remove intake manifold flap motor V157 ⇒ 4-cylinder diesel

engine (2 valve); Rep. Gr. 23 ; Removing and installing mix‐ ture preparation - injection .

2.0 l diesel engine:

– Touran vehicles only: remove plenum chamber middle bulk‐

head ⇒ General body repairs, exterior; Rep. Gr. 50 ; Assem‐ bly overview - plenum chamber bulkhead .

– Remove connecting pipe between intake hose and turbo‐

charger.

– Remove toothed belt guard upper part.

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

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

Diesel engines with diesel particulate filter:

– Unscrew exhaust gas pressure sensor 1 -G450- , separate

electrical connectors, unscrew and lower diesel particulate fil‐ ter ⇒ Rep. Gr. 26 ; Assembly overview - front exhaust pipe with particulate filter .

Continuation for all vehicles:

– Remove heat shield (if installed).

– Release connector on control unit in direction of arrow -1- and

pull off -2-.

– Apply brake pedal depressor -V.A.G 1869/2- .

– Connect bleeder bottle hose to front left brake caliper bleeder

valve and rear left brake caliper bleeder valve and open bleed‐ er valves.

– Depress brake pedal at least 60 mm using brake pedal de‐

pressor -V.A.G 1869/2- .

– Close front left and rear left bleeder valve.

– Do not remove brake pedal depressor -V.A.G 1869/2- .

– Place sufficient lint-free cloths under the control unit and hy‐

draulic unit.

Ensure no brake fluid gets onto contacts.

Brake systems - Edition 05.2008

– First identify the two brake master cylinder brake lines

-A and B- and unscrew from the hydraulic unit.

– Immediately seal brake lines and threaded holes with seal

plugs from repair set Part No. 1H0 698 311 A.

– Identify brake lines (brake calipers) -1 to 4-, unscrew and seal.

– Turn hexagon fitted bolt out of retainer.

– Pull hydraulic unit together with control unit and retainer side‐

ways out of rubber dampers of bracket and turn upside down.

– Unbolt retainer from hydraulic unit in engine compartment and

remove.

– Remove hydraulic unit together with control unit.

6.4.3 Unbolting control unit from hydraulic unit

Note

– Place hydraulic unit with control unit upwards on a clean flat

level surface.

– Unscrew Torx socket head bolts out of control unit.

6. Assembly overview - hydraulic unit, brake servo/brake master cylinder 53

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

– Without canting it, pull control unit off from hydraulic unit

-arrow-.

– Carefully pull all seals from hydraulic unit contact pins.

WARNING

♦ The printed circuit board becomes visible when the control

unit is removed.

♦ No moisture or particles of dirt may enter the control unit.

♦ Avoid electrostatic charge!

– Cover control unit solenoids with a lint-free cloth.

After separating control unit and hydraulic unit, use transport pro‐ tection for contact pins.

6.4.4 Installing new control unit

WARNING

Severe shocks (e.g. dropping, impact) may destroy the control unit. The control unit must not then be used.

• Clean surfaces before assembling.

– Push all seals -A- over contact pins slightly.

– Without canting it, place control unit onto hydraulic unit.

The seals are thus moved to end position.

– Tighten hydraulic unit and control unit diagonally in stages to

specified torque with enclosed new Torx socket head bolts.

Note

♦

A new control unit may be mounted on an existing hydraulic unit max. twice to guarantee impermeability of the elastic seal.

♦

A control unit which has already been operated in a vehicle must not be installed a second time.

6.4.5 Installing control unit and hydraulic unit

Note

♦

Remove sealing plugs from new hydraulic unit only when the corresponding brake line is going to be fitted.

♦

If sealing plugs are removed too early from the hydraulic unit, brake fluid can escape, and it can then no longer be guaran‐ teed that the unit can be sufficiently filled and bled.

– Install in reverse order.

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

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

WARNING

Ensure that rubber dampers of retainer are not pressed out of bracket when installing. After installing, check hydraulic unit with control unit for proper seating, otherwise malfunctions can occur.

– Remove brake pedal depressor -V.A.G 1869/2- .

– Bleed brake system ⇒ page 130 .

– Code radio.

– Code control unit -J104- with ⇒ Vehicle diagnosis, testing and

information system VAS 5051 in ”Guided fault finding”.

To do this, basic setting of the steering angle sender -G85- , the lateral acceleration sender -G200- and the brake pressure sender

-G201- must be carried out.

Specified torques: Control unit to hydraulic unit

♦ Use new bolts!

2 Nm + 0.8

Nm

Brake systems - Edition 05.2008

Torx bolt of hydraulic unit to bracket 8 Nm Hexagon fitted bolt, retainer to bracket 8 Nm Brake lines to ABS assembly: Thread M 10 x 1 14 Nm Thread M 12 x 1 14 Nm

6. Assembly overview - hydraulic unit, brake servo/brake master cylinder 55

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

7 Removing and installing parts of ABS

system on front and rear axle

7.1 Removing and installing parts of ABS system on front axle

1 - ABS speed sensor

❑ Before inserting sensor,

clean hole inner surface and coat with high-tem‐ perature paste G 052 112 A3.

❑ Removing and installing

⇒ page 56

2 - Hexagon socket head bolt, 8 Nm

3 - Wheel bearing/hub unit

❑ ABS sensor ring is in‐

stalled in the wheel bearing.

4 - Drive shaft

7.1.1 Removing and installing speed sensor on front axle

Removing

– Raise vehicle.

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

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

Brake systems - Edition 05.2008

– Separate connector -1- from speed sensor wire and from

speed sensor.

– Remove bolt -2- from wheel bearing housing.

– Pull ABS speed sensor out of wheel bearing housing.

Installing

– Before inserting speed sensor, clean hole inner surface and

coat speed sensor all-round with high-temperature paste G 052 112 A3.

– Insert speed sensor into hole in wheel bearing housing and

tighten bolt to 8 Nm.

– Connect speed sensor to speed sensor wire.

7.2 Removing and installing parts of anti-lock brake system on rear axle (frontwheel drive)

1 - ABS speed sensor

❑ Before inserting sensor,

clean hole inner surface and coat with high-tem‐ perature paste G 052 112 A3.

❑ Removing and installing

⇒ page 58

2 - Hexagon socket head bolt, 8 Nm

3 - Wheel bearing/hub unit

❑ ABS sensor ring is in‐

stalled in the wheel bearing.

7. Removing and installing parts of ABS system on front and rear axle 57

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

7.2.1 Removing and installing speed sensor on rear axle

Removing

– Raise vehicle.

– Separate connector -1- from speed sensor wire and from

speed sensor.

– Remove bolt -2- from wheel bearing housing.

– Pull ABS speed sensor out of wheel bearing housing.

Installing

– Before inserting speed sensor, clean hole inner surface and

coat speed sensor all-round with high-temperature paste G 052 112 A3.

– Insert speed sensor into hole in wheel bearing housing and

tighten bolt to 8 Nm.

– Connect speed sensor to speed sensor wire.

7.3 Removing and installing parts of anti-lock brake system on rear axle (fourwheel drive)

1 - ABS speed sensor

❑ Before inserting sensor,

clean hole inner surface and coat with high-tem‐ perature paste G 052 112 A3.

❑ Removing and installing

⇒ page 59

2 - Hexagon socket head bolt, 8 Nm

3 - Wheel bearing/hub unit

❑ ABS sensor ring is in‐

stalled in the wheel bearing.

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

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

7.3.1 Removing and installing speed sensor on rear axle

Removing

– Raise vehicle.

– Separate connector -1- from speed sensor wire and from

speed sensor.

– Remove bolt -2- from wheel bearing housing.

– Pull ABS speed sensor out of wheel bearing housing.

Installing

– Before inserting speed sensor, clean hole inner surface and

coat speed sensor all-round with high-temperature paste G 052 112 A3.

– Insert speed sensor into hole in wheel bearing housing and

tighten bolt to 8 Nm.

– Connect speed sensor to speed sensor wire.

Brake systems - Edition 05.2008

7. Removing and installing parts of ABS system on front and rear axle 59

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

8 Removing and installing parts of ESP

system

8.1 Removing and installing ESP sensor unit -G419- (Touran)

The lateral acceleration sender -G200- , the yaw rate sender G202- and the longitudinal acceleration sender -G251- are in‐ stalled together in one housing behind the glove compartment.

After exchanging the ESP sensor unit -G419- , perform basic set‐ ting for lateral acceleration sender -G200- .

WARNING

Severe shocks (e.g. dropping, impact) may destroy the ESP sensor unit -G419- . The ESP sensor unit -G419- may not then be used any further.

Removing

– Remove glove compartment ⇒ General body repairs, interior;

Rep. Gr. 68 ; Compartments, covers and trims .

– Pull connector -1- off ESP sensor unit -G419- .

– Remove the two securing nuts -arrows-.

– Remove ESP sensor unit -G419- .

Installing

– Install in reverse order.

When installing the ESP sensor unit -G419- , make sure it is cor‐ rectly seated in its bracket and is free of stress.

Note

Do not use the securing nuts to forcibly position the ESP sensor unit -G419- .

– Tighten securing nuts to 9 Nm.

– Perform basic setting of lateral acceleration sender -G200- .

Connecting -VAS 5051- and selecting functions ⇒ page 13 .

8.2 Removing and installing ESP sensor unit -G419- (Golf, Eos)

The lateral acceleration sender -G200- , the yaw rate sender G202- and the longitudinal acceleration sender -G251- are in‐ stalled in a housing under the right front seat.

After exchanging the ESP sensor unit -G419- , perform basic set‐ ting for lateral acceleration sender -G200- .

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

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

WARNING

Severe shocks (e.g. dropping, impact) may destroy the ESP sensor unit -G419- . The ESP sensor unit -G419- may not then be used any further.

Removing

– Remove right front seat together with seat frame ⇒ General

body repairs, interior; Rep. Gr. 72 .

– Remove sill panel trim ⇒ General body repairs, interior; Rep.

Gr. 68 ; Sill panel trims .

– Lift carpet and lay to the side.

– Remove coupling station -1-.

– Raise floor covering.

– Pull connector -1- off ESP sensor unit -G419- .

– Remove the two securing nuts -arrows-.

– Remove ESP sensor unit -G419- .

Installing

– Install in reverse order.

When installing the ESP sensor unit -G419- , make sure it is cor‐ rectly seated in its bracket and is free of stress.

Note

Do not use the securing nuts to forcibly position the ESP sensor unit -G419- .

– Tighten securing nuts to 9 Nm.

– Perform basic setting of lateral acceleration sender -G200- .

Connecting -VAS 5051- and selecting functions ⇒ page 13 .

Brake systems - Edition 05.2008

8.3 Removing and installing steering angle sender -G85-

The steering angle sender -G85- is located between the steering wheel and steering column switch.

Removing and installing

⇒ Electrical system; Rep. Gr. 94 ; Lights, bulbs, switches - ex‐ terior; Steering column switch .

– Then perform basic setting of steering angle sender -G85- .

Connecting -VAS 5051- and selecting functions ⇒ page 13 .

8. Removing and installing parts of ESP system 61

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

Note

In vehicles equipped with an electromechanical power steering of the 3rd generation, the steering angle sender is located in the steering box from week 22/2008.

8.4 Removing and installing brake servo vacuum sender -G483-

Removing

– Removing and installing battery ⇒ Electrical system; Rep. Gr.

27 ; Removing and installing battery .

– Remove battery tray.

– Disconnect connector -1- from brake servo vacuum sender -

G483- -2-.

– Insert screwdriver into circlip groove between stop and one

end of circlip.

– Now press circlip -1- out of groove until brake servo vacuum

sender -G483- -2- can be pulled out of brake servo.

Installing

– Install in reverse order.

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

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

46 – Brakes - mechanism

1 Repairing front brakes

1.1 Repairing front brakes, FS III brake cal‐ iper

Note

♦

Every time after changing pads, depress brake pedal firmly several times with vehicle stationary, so that brake pads are properly seated in their normal operating position.

♦

Use the brake filling and bleeding equipment -VAS 5234- or the extraction unit -V.A.G 1869/4- to draw off brake fluid from the brake fluid reservoir.

♦

Before removing a brake caliper or disconnecting a brake hose, fit brake pedal depressor -V.A.G 1869/2- (when doing this, release pressure in system).

1 - Hexagon bolt / Torx bolt, 12 Nm

❑ M6x10 hexagon bolt re‐

vised to M6x12 Torx bolt

❑ Replace hexagon bolt

with hexagon bolt and Torx bolt with Torx bolt

2 - Brake disc

❑ Ventilated, ∅ 280 mm ❑ Thickness: 22 mm ❑ Wear limit: 19 mm ❑ Always renew on both

sides of an axle.

❑ Unscrew brake caliper

prior to removing.

3 - Cross head screw / Torx screw, 4 Nm

4 - Brake pads

❑ Thickness: 14 mm with‐

out backplate

❑ With break pad wear in‐

dicator

❑ When wear reaches a

predetermined limit (ap‐ prox. 4 mm) the warning lamp in the dash panel insert comes on.

❑ Pad wear limit: 2 mm

without backplate

❑ Check thickness

⇒ Maintenance ; Book‐ let 18.1 .

❑ Always renew on both

sides of an axle.

Brake systems - Edition 05.2008

1. Repairing front brakes 63

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

❑ Removing and installing ⇒ page 64

5 - Connector

❑ Brake pad wear indicator

6 - Brake caliper

❑ Do not disconnect brake hose when changing pads. ❑ Removing and installing ⇒ page 67 ❑ Repairing ⇒ page 113

7 - Guide pin, 30 Nm

8 - Cover cap

❑ Remove

9 - Brake hose with banjo union and banjo bolt, 35 Nm

10 - Guide pin, 30 Nm

11 - Cover cap

❑ Remove

12 - Bolt

13 - Bracket

14 - Wheel bearing housing

❑ With integrated brake carrier.

15 - ABS speed sensor

❑ Before inserting sensor, clean hole inner surface and coat with high-temperature paste G 052 112 A3.

16 - Hexagon socket head bolt, 8 Nm

17 - Wheel bearing/hub unit

❑ ABS sensor ring is installed in the wheel bearing.

18 - Splash plate

1.2 Removing and installing brake pads/lin‐ ings

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

64 Rep. Gr.46 - Brakes - mechanism

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

♦ Piston resetting tool -T 10145-

1.2.1 Removing

Mark brake pads when removing if they are to be reused. Fit in same position when installing, or braking will be uneven.

– Remove wheels.

– Disconnect connector -1- for brake pad wear indicator.

Brake systems - Edition 05.2008

– Remove cover caps -arrows-.

1. Repairing front brakes 65

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

– Unscrew both guide pins -arrows- and remove from brake cal‐

iper.

– Remove brake caliper and secure with wire so that weight of

brake caliper does not strain or damage brake hose.

– Take brake pads out of brake caliper.

Cleaning:

WARNING

Do not blow out brake system with compressed air; the result‐ ing dust constitutes a health hazard!

– Thoroughly clean brake carrier and contact surfaces for brake

pads and remove corrosion.

– Clean brake caliper.

Use only methylated spirits for cleaning the brake caliper housing.

1.2.2 Installing

Before pressing piston back into cylinder with piston resetting tool, draw off brake fluid from brake fluid reservoir. Otherwise, partic‐ ularly if reservoir has been topped up, fluid will overflow and cause damage.

– Press piston back.

– Insert inner brake pad (piston side) -1- and outer brake pad

-2- into brake caliper with retaining springs.

♦ Inner brake pad (piston side) with large 3-finger clip -1-.

♦ Outer brake pad with small 3-finger clip -2- (coloured black).

66 Rep. Gr.46 - Brakes - mechanism

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

– First position brake caliper with brake pads at bottom -arrow-

of brake carrier.

– Bolt brake caliper to brake carrier with both guide pins.

• Brake caliper stud must be positioned behind brake carrier guide!

– Fit both cover caps.

– Reconnect connector for brake pad wear indicator.

– Fit wheels.

Specified torque of wheel bolts ⇒ Running gear, axles, steering; Rep. Gr. 44 ; Specified torques of wheel bolts .

Note

♦

Every time after changing pads, depress brake pedal firmly several times with vehicle stationary, so that brake pads are properly seated in their normal operating position.

♦

Check brake fluid level after changing brake pads.

Specified torque: Guide pin to brake carrier 30 Nm

1.3 Removing and installing brake caliper

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

Brake systems - Edition 05.2008

1. Repairing front brakes 67

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

♦ Brake pedal depressor -V.A.G 1869/2-

1.3.1 Removing

This procedure applies only to exchanging or the following repair work on the brake caliper.

– Remove wheels.

– Separate connector for brake pad wear indicator.

– Connect bleeder bottle hose to brake caliper bleeder valve and

open bleeder valve.

– Apply brake pedal depressor -V.A.G 1869/2- .

– Close bleeder valve and remove bleeder bottle.

– Disconnect brake hose.

– Pull both cover caps out of sleeve bearings of brake caliper.

– Loosen both guide pins and remove from brake caliper.

– Pull brake caliper off brake carrier.

– Remove brake pads from brake caliper.

1.3.2 Installing

• Piston is pressed back.

– Insert inner brake pad (piston side) -1- and outer brake pad

♦ Inner brake pad (piston side) with large 3-finger clip -1-.

♦ Outer brake pad with small 3-finger clip -2- (coloured black).

-2- into brake caliper with retaining springs.

68 Rep. Gr.46 - Brakes - mechanism

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

– First position brake caliper with brake pads at bottom -arrow-

of brake carrier.

– Bolt brake caliper to brake carrier with both guide pins.

• Brake caliper stud must be positioned behind brake carrier guide!

– Fit both cover caps.

– Bolt brake hose to brake caliper.

– Remove brake pedal depressor -V.A.G 1869/2- .

– Reconnect connector for brake pad wear indicator.

– Bleed brake system ⇒ page 130 .

– Fit wheels.

Specified torque of wheel bolts ⇒ Running gear, axles, steering; Rep. Gr. 44 ; Specified torques of wheel bolts .

Note

♦

Firmly depress brake pedal several times with vehicle station‐ ary, so that the brake pads are properly seated in their normal operating position.

♦

Check brake fluid level.

Brake systems - Edition 05.2008

Specified torques: Guide pin to brake carrier 30 Nm Brake hose to brake caliper 35 Nm

1.4 Repairing front brake, FN 3 brake cali‐

per

Note

♦

Every time after changing pads, depress brake pedal firmly several times with vehicle stationary, so that brake pads are properly seated in their normal operating position.

♦

Use the brake filling and bleeding equipment -VAS 5234- or the extraction unit -V.A.G 1869/4- to draw off brake fluid from the brake fluid reservoir.

♦

Before removing a brake caliper or disconnecting a brake hose, fit brake pedal depressor -V.A.G 1869/2- (when doing this, release pressure in system).

Assembly overview, FN3, 15 inches:

1. Repairing front brakes 69

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

1 - Cross head screw / Torx screw, 4 Nm

2 - Brake disc

❑ Ventilated, ∅ 288 mm ❑ Thickness: 25 mm ❑ Wear limit: 22 mm ❑ Always renew on both

sides of an axle.

❑ Remove brake caliper

and brake carrier prior to removing.

3 - Brake pads

❑ Thickness: 14 mm with‐

out backplate

❑ With break pad wear in‐

dicator

❑ When wear reaches a

predetermined limit (ap‐ prox. 4 mm) the warning lamp in the dash panel insert comes on.

❑ Pad wear limit: 2 mm

without backplate

❑ Check thickness

⇒ Maintenance ; Book‐ let 18.1 .

❑ Always renew on both

sides of an axle.

❑ Removing and installing

⇒ page 72

4 - Retaining spring

❑ Insert into both holes in

brake caliper.

5 - Brake carrier

❑ Bolt to wheel bearing housing.

6 - Brake caliper

❑ Do not disconnect brake hose when changing pads. ❑ Removing and installing ⇒ page 75 ❑ Repairing ⇒ page 113

7 - Guide pin, 30 Nm

8 - Cover cap

❑ Remove

9 - Brake hose with banjo union and banjo bolt, 35 Nm

10 - Ribbed bolt, 190 Nm

❑ Clean if reused.

11 - Bolt

12 - Bracket

13 - Wheel bearing housing

❑ With bolted brake carrier.

14 - ABS speed sensor

❑ Before inserting sensor, clean hole inner surface and coat with high-temperature paste G 052 112 A3.

70 Rep. Gr.46 - Brakes - mechanism

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

15 - Hexagon socket head bolt, 8 Nm

16 - Splash plate

17 - Hexagon bolt / Torx bolt, 12 Nm

❑ M6x10 hexagon bolt revised to M6x12 Torx bolt ❑ Replace hexagon bolt with hexagon bolt and Torx bolt with Torx bolt

18 - Wheel bearing/hub unit

❑ ABS sensor ring is installed in the wheel bearing.

Assembly overview, FN3, 16 inches:

1 - Torx bolt, 12 Nm

2 - Brake disc

❑ Ventilated, ∅ 312 mm ❑ Thickness: 25 mm ❑ Wear limit: 22 mm ❑ Always renew on both

sides of an axle.

❑ Remove brake caliper

and brake carrier prior to removing.

3 - Torx bolt, 4 Nm

4 - Brake pads

❑ Thickness: 14 mm with‐

out backplate

❑ With break pad wear in‐

dicator

❑ When wear reaches a

predetermined limit (ap‐ prox. 4 mm) the warning lamp in the dash panel insert comes on.

❑ Pad wear limit: 2 mm

without backplate

❑ Check thickness

⇒ Maintenance ; Book‐ let 18.1 .

❑ Always renew on both

sides of an axle.

❑ Removing and installing

⇒ page 72

5 - Retaining spring

❑ Insert into both holes in

brake caliper.

6 - Brake carrier

❑ Bolt to wheel bearing housing.

7 - Brake caliper

❑ Do not disconnect brake hose when changing pads. ❑ Removing and installing ⇒ page 75 ❑ Repairing ⇒ page 113

Brake systems - Edition 05.2008

1. Repairing front brakes 71

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

8 - Guide pin, 30 Nm

9 - Cover cap

❑ Remove

10 - Brake hose with banjo union and banjo bolt, 35 Nm

11 - Guide pin, 30 Nm

12 - Cover cap

❑ Remove

13 - Bolt

14 - Bracket

15 - Ribbed bolt, 190 Nm

❑ Clean if reused.

16 - Wheel bearing housing

❑ With bolted brake carrier.

17 - ABS speed sensor

❑ Before inserting sensor, clean hole inner surface and coat with high-temperature paste G 052 112 A3.

18 - Hexagon socket head bolt, 8 Nm

19 - Wheel bearing/hub unit

❑ ABS sensor ring is installed in the wheel bearing.

20 - Splash plate

1.5 Removing and installing brake pads/lin‐ ings

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

♦ Piston resetting tool -T 10145-

72 Rep. Gr.46 - Brakes - mechanism

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

1.5.1 Removing

Mark brake pads when removing if they are to be reused. Fit in same position when installing, or braking will be uneven.

– Remove wheels.

– Lever brake pad retaining spring out from brake caliper

-arrow- with a screwdriver and remove.

– Disconnect connector -1- for brake pad wear indicator.

Brake systems - Edition 05.2008

– Remove cover caps -arrows-.

1. Repairing front brakes 73

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

– Unscrew both guide pins -arrows- and remove from brake cal‐

iper.

– Remove brake caliper and secure with wire so that weight of

brake caliper does not strain or damage brake hose.

– Take brake pad out of brake caliper or from brake carrier.

Cleaning:

WARNING

Do not blow out brake system with compressed air; the result‐ ing dust constitutes a health hazard!

– Thoroughly clean brake carrier and contact surfaces for brake

pads and remove corrosion.

– Clean brake caliper, in particular the bonding surface for the

brake pad. It must be free of adhesive and grease residues.

Use only methylated spirits for cleaning the brake caliper housing.

1.5.2 Installing

Before pressing piston back into cylinder with piston resetting tool, draw off brake fluid from brake fluid reservoir. Otherwise, partic‐ ularly if reservoir has been topped up, fluid will overflow and cause damage.

– Press piston back.

– Pull protective foil off outer brake pad backplate.

– Fit outer brake pad to brake carrier.

– Insert inner brake pad with retaining spring into brake caliper

(piston).

When positioning the brake caliper, ensure that the brake pad does not stick to the brake caliper housing before it is positioned correctly.

Do not damage adhesive surface.

74 Rep. Gr.46 - Brakes - mechanism

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

– Bolt brake caliper to brake carrier with both guide pins.

– Fit both cover caps.

– Insert retaining spring into brake caliper.

– Reconnect connector for brake pad wear indicator.

– Fit wheels.

Specified torque of wheel bolts ⇒ Running gear, axles, steering; Rep. Gr. 44 ; Specified torques of wheel bolts .

Note

♦

Every time after changing pads, depress brake pedal firmly several times with vehicle stationary, so that brake pads are properly seated in their normal operating position.

♦

Check brake fluid level after changing brake pads.

Specified torque: Guide pin to brake carrier 30 Nm

1.6 Removing and installing brake caliper

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

Brake systems - Edition 05.2008

♦ Brake pedal depressor -V.A.G 1869/2-

1.6.1 Removing

This procedure applies only to exchanging or the following repair work on the brake caliper.

– Remove wheels.

– Lever brake pad retaining spring out from brake caliper with a

screwdriver and remove.

1. Repairing front brakes 75

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

– Separate connector for brake pad wear indicator.

– Connect bleeder bottle hose to brake caliper bleeder valve and

open bleeder valve.

– Apply brake pedal depressor -V.A.G 1869/2- .

– Close bleeder valve and remove bleeder bottle.

– Disconnect brake hose.

– Pull both cover caps out of sleeve bearings of brake caliper.

– Loosen both guide pins and remove from brake caliper.

– Pull brake caliper off brake carrier.

– Remove brake pads from brake caliper.

1.6.2 Installing

• Piston is pressed back.

• Outer brake pad is seated on brake carrier.

– Insert inner brake pad with retaining spring into brake caliper

(piston).

When positioning the brake caliper, ensure that the brake pad does not stick to the brake caliper housing before it is positioned correctly.

Do not damage adhesive surface.

– Bolt brake caliper to brake carrier with both guide pins.

– Fit both cover caps.

– Bolt brake hose to brake caliper.

– Remove brake pedal depressor -V.A.G 1869/2- .

– Insert retaining spring into brake caliper.

– Reconnect connector for brake pad wear indicator.

– Bleed brake system ⇒ page 130 .

– Fit wheels.

Specified torque of wheel bolts ⇒ Running gear, axles, steering; Rep. Gr. 44 ; Specified torques of wheel bolts .

Note

♦

Firmly depress brake pedal several times with vehicle station‐ ary, so that the brake pads are properly seated in their normal operating position.

♦

Check brake fluid level.

Specified torques: Guide pin to brake carrier 30 Nm Brake hose to brake caliper 35 Nm

76 Rep. Gr.46 - Brakes - mechanism

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

1.7 Repairing front brake, FNR-G brake cal‐ iper

Note

♦

Every time after changing pads, depress brake pedal firmly several times with vehicle stationary, so that brake pads are properly seated in their normal operating position.

♦

Use the brake filling and bleeding equipment -VAS 5234- or the extraction unit -V.A.G 1869/4- to draw off brake fluid from the brake fluid reservoir.

♦

Before removing a brake caliper or disconnecting a brake hose, fit brake pedal depressor -V.A.G 1869/2- (when doing this, release pressure in system).

1 - Splash plate

2 - Torx bolt, 12 Nm

3 - Brake disc

❑ Ventilated, ∅ 345 mm ❑ Thickness: 30 mm ❑ Wear limit: 27 mm ❑ Always renew on both

sides of an axle.

❑ Remove brake caliper

and brake carrier prior to removing.

4 - Torx bolt, 4 Nm

5 - Brake carrier

❑ Bolt to wheel bearing

housing.

6 - Retaining spring

❑ Insert into brake pad re‐

taining spring and press under brake carrier.

7 - Ribbed bolt, 190 Nm

❑ Clean if reused.

8 - Brake pads

❑ Thickness: 14 mm with‐

out backplate

❑ With break pad wear in‐

dicator

❑ When wear reaches a

predetermined limit (ap‐ prox. 4 mm) the warning lamp in the dash panel insert comes on.

❑ Pad wear limit: 2 mm

without backplate ❑ Check thickness ⇒ Maintenance ; Booklet 18.1 . ❑ Always renew on both sides of an axle. ❑ Removing and installing ⇒ page 78

Brake systems - Edition 05.2008

1. Repairing front brakes 77

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

9 - Brake caliper

❑ Do not disconnect brake hose when changing brake pads. ❑ Must not be unbolted from one another. ❑ Removing and installing ⇒ page 81 ❑ Repairing ⇒ page 119

10 - Guide pin, 30 Nm

11 - Cover cap

❑ Remove

12 - Washer

13 - Balance weight

14 - Bolt, 10 Nm

15 - Dust cap

16 - Retainer

17 - Bolt, 15 Nm

18 - Brake line, 14 Nm

19 - Brake hose

20 - Hexagon socket head bolt, 8 Nm

21 - Retainer

22 - Spring clip

1.8 Removing and installing brake pads/lin‐ ings

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

♦ Piston resetting tool -T 10145-

78 Rep. Gr.46 - Brakes - mechanism

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

1.8.1 Removing

Mark brake pads when removing if they are to be reused. Fit in same position when installing, or braking will be uneven.

– Remove wheels.

– Lever brake caliper retaining spring out of brake pad retaining

spring using a screwdriver. To do this, position screwdriver between the two retaining springs -enlargement-.

– Firmly hold brake caliper retaining spring with a cloth to pre‐

vent loss.

– Disconnect connector -1- for brake pad wear indicator.

Brake systems - Edition 05.2008

– Remove cover caps -arrows-.

1. Repairing front brakes 79

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

– Unscrew both guide pins -arrows- and remove from brake cal‐

iper.

– Remove brake caliper and secure with wire so that weight of

brake caliper does not strain or damage brake hose.

– Take brake pads out of brake caliper.

Cleaning:

WARNING

Do not blow out brake system with compressed air; the result‐ ing dust constitutes a health hazard!

– Thoroughly clean brake carrier and contact surfaces for brake

pads and remove corrosion.

– Clean brake caliper.

Use only methylated spirits for cleaning the brake caliper housing.

1.8.2 Installing

Before pressing piston back into cylinder with piston resetting tool, draw off brake fluid from brake fluid reservoir. Otherwise, partic‐ ularly if reservoir has been topped up, fluid will overflow and cause damage.

– Press piston back.

– Insert inner brake pad with retaining spring into brake caliper

(piston).

80 Rep. Gr.46 - Brakes - mechanism

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

– Insert outer brake pad -2- with retaining spring in caliper.

– Fit brake caliper with brake pads onto brake carrier.

– Bolt brake caliper to brake carrier with both guide pins.

– Fit both cover caps.

– Insert brake caliper retaining spring into brake pad retaining

spring and press under brake carrier.

– Reconnect connector for brake pad wear indicator.

– Fit wheels.

Specified torque of wheel bolts ⇒ Running gear, axles, steering; Rep. Gr. 44 ; Specified torques of wheel bolts .

♦

Every time after changing pads, depress brake pedal firmly

Note

several times with vehicle stationary, so that brake pads are properly seated in their normal operating position.

♦

Check brake fluid level after changing brake pads.

Specified torque: Guide pin to brake carrier 30 Nm

1.9 Removing and installing brake caliper

Brake systems - Edition 05.2008

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

1. Repairing front brakes 81

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

♦ Brake pedal depressor -V.A.G 1869/2-

1.9.1 Removing

This procedure applies only to exchanging or the following repair work on the brake caliper.

– Remove wheels.

– Lever brake caliper retaining spring out of brake pad retaining

spring using a screwdriver. To do this, position screwdriver between both retaining springs.

– Firmly hold brake caliper retaining spring with a cloth to pre‐

vent loss.

– Separate connector for brake pad wear indicator.

– Connect bleeder bottle hose to brake caliper bleeder valve and

open bleeder valve.

– Apply brake pedal depressor -V.A.G 1869/2- .

– Close bleeder valve and remove bleeder bottle.

– Disconnect brake hose.

– Pull both cover caps out of sleeve bearings of brake caliper.

– Loosen both guide pins and remove from brake caliper.

– Pull brake caliper off brake carrier.

– Remove brake pads from brake caliper.

1.9.2 Installing

• Piston is pressed back.

– Insert inner brake pad with retaining spring into brake caliper

(piston).

– Insert outer brake pad with retaining spring in brake caliper.

– Fit brake caliper with brake pads onto brake carrier.

– Bolt brake caliper to brake carrier with both guide pins.

– Fit both cover caps.

– Connect brake hose to brake line from brake caliper.

– Remove brake pedal depressor -V.A.G 1869/2- .

– Insert brake caliper retaining spring into brake pad retaining

spring and press under brake carrier.

– Reconnect connector for brake pad wear indicator.

– Bleeding brake system

– Fit wheels.

82 Rep. Gr.46 - Brakes - mechanism

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

Specified torque of wheel bolts ⇒ Running gear, axles, steering; Rep. Gr. 44 ; Specified torques of wheel bolts .

Note

♦

Firmly depress brake pedal several times with vehicle station‐ ary, so that the brake pads are properly seated in their normal operating position.

♦

Check brake fluid level.

Specified torques: Guide pin to brake carrier 30 Nm Brake hose to brake line 14 Nm

Brake systems - Edition 05.2008

1. Repairing front brakes 83

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

2 Repairing rear brake

2.1 Repairing rear brake CI 38

♦

1 - ABS speed sensor

❑ Before inserting sensor,

Note

Every time after changing pads, depress brake pedal firmly several times with vehicle stationary, so that brake pads are properly seated in their normal operating position.

Use the brake filling and bleeding equipment -VAS 5234- or the extraction unit -V.A.G 1869/4- to draw off brake fluid from the brake fluid reservoir.

Before removing a brake caliper or disconnecting a brake hose, fit brake pedal depressor -V.A.G 1869/2- (when doing this, release pressure in system).

clean hole inner surface and coat with high-tem‐ perature paste G 052 112 A3.

2 - Hexagon socket head bolt, 8 Nm

3 - Multi-point socket head bolt, 90 Nm and turn 90° further

❑ Always renew after re‐

moving

4 - Wheel bearing housing

5 - Splash plate

6 - Hexagon bolt, 9 Nm / Torx bolt, 12 Nm

❑ M6x10 hexagon bolt re‐

vised to M6x12 Torx bolt

❑ Replace hexagon bolt

with hexagon bolt and Torx bolt with Torx bolt

7 - Wheel bearing/hub unit

8 - Brake disc

❑ ∅ 255 mm ❑ Thickness: 10 mm ❑ Wear limit: 8 mm ❑ When worn, renew on

both sides of axle.

❑ Unscrew brake caliper

prior to removing.

9 - Cross-head screw, 4 Nm

10 - Bolt

11 - Brake pads

❑ Thickness: 11 mm without backplate

84 Rep. Gr.46 - Brakes - mechanism

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

❑ Pad wear limit: 2 mm without backplate ❑ Check thickness ⇒ Maintenance ; Booklet 18.1 . ❑ Always renew on both sides of an axle. ❑ Removing and installing ⇒ page 85

12 - Brake carrier with guide pin(s) and protective cap

❑ Supplied as genuine part, assembled with sufficient grease on guide pins. ❑ If protective caps or guide pins are damaged, install repair kit. Use lubricant sachet supplied to lubricate

guide pins.

13 - Brake caliper

❑ Do not disconnect brake hose when changing pads. ❑ Removing and installing ⇒ page 87 ❑ Repairing ⇒ page 124 ❑ Adjust handbrake cable first after repairing or replacement. ❑ Adjusting handbrake ⇒ page 101 .

14 - Hose retainer

15 - Brake line, 14 Nm

16 - Self-locking hexagon bolt, 35 Nm

❑ Renew.

17 - Handbrake cable

❑ Adjusting handbrake ⇒ page 101 .

18 - Spring clip

Brake systems - Edition 05.2008

19 - Brake hose

2.2 Removing and installing brake pads/lin‐ ings

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

2. Repairing rear brake 85

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

♦ Resetting and removal tool -T 10165-

2.2.1 Removing

Mark brake pads when removing if they are to be reused. Fit in same position when installing, or braking will be uneven.

– Remove wheels.

– Remove securing bolts from brake caliper, to do this counter‐

hold on guide pins.

– Remove brake caliper and secure with wire so that weight of

brake caliper does not strain or damage brake hose.

– Remove brake pads.

Cleaning:

WARNING

Do not blow out brake system with compressed air; the result‐ ing dust constitutes a health hazard!

– Thoroughly clean brake carrier and contact surfaces for brake

pads and remove corrosion.

– Clean brake caliper, particularly the bonding surfaces for the

brake pads. These must be free of adhesive and grease res‐ idues.

Use only methylated spirits for cleaning the brake caliper housing.

2.2.2 Installing

Before pressing pistons back, draw off some brake fluid from res‐ ervoir with a bleeder bottle. Otherwise, particularly if reservoir has been topped up, fluid will overflow and cause damage.

– Screw in piston by turning knurled wheel of resetting and re‐

moval tool - T 10165 - clockwise, do not damage protective cap when doing this.

86 Rep. Gr.46 - Brakes - mechanism

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

– To aid screwing in, use special tool T10165/1.

♦ If pistons are difficult to move, use a 13 mm open jaw spanner

on flats -arrow A- provided for this purpose.

– Pull protective foil off backing plates for brake pads.

– Insert brake pads into brake carrier.

When positioning the brake caliper, ensure that the brake pads do not stick to the brake caliper before it is positioned correctly.

– Secure brake caliper with new self-locking bolts.

♦ The repair kit includes four self-locking hexagon bolts which

must always be installed.

– Fit wheels.

Specified torque of wheel bolts ⇒ Running gear, axles, steering; Rep. Gr. 44 ; Specified torques of wheel bolts .

Brake systems - Edition 05.2008

Note

♦

Every time after changing pads, depress brake pedal firmly several times with vehicle stationary, so that brake pads are properly seated in their normal operating position.

♦

Check brake fluid level after changing brake pads.

Specified torque: Hexagon bolt, brake caliper to brake carrier

♦ Use new bolts!

2.3 Removing and installing brake caliper

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

35 Nm

2. Repairing rear brake 87

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

♦ Brake pedal depressor -V.A.G 1869/2-

2.3.1 Removing

This procedure applies only to exchanging or the following repair work on the brake caliper.

– Remove wheels.

– Unclip brake cable from lever on brake caliper.

– Pull spring clip downwards and pull handbrake cable out of

retainer on brake caliper.

– Connect bleeder bottle hose to brake caliper bleeder valve and

open bleeder valve.

– Apply brake pedal depressor -V.A.G 1869/2- .

– Close bleeder valve and remove bleeder bottle.

– Unscrew brake line.

– Remove both securing bolts from brake caliper; to do this,

counterhold on guide pin.

– Pull brake caliper off brake carrier.

2.3.2 Installing

• Piston is pressed back.

• The brake pads are seated on the brake carrier.

– Secure brake caliper to brake carrier with new self-locking

bolts.

– Screw brake line to brake caliper.

– Bleed brake system ⇒ page 130 .

– Hook in handbrake cable and secure on retainer with spring

clip.

– Adjusting handbrake ⇒ page 101 .

– Fit wheels.

Specified torque of wheel bolts ⇒ Running gear, axles, steering; Rep. Gr. 44 ; Specified torques of wheel bolts .

88 Rep. Gr.46 - Brakes - mechanism

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

Note

♦

Firmly depress brake pedal several times with vehicle station‐ ary, so that the brake pads are properly seated in their normal operating position.

♦

Check brake fluid level.

Specified torques: Hexagon bolt, brake caliper to brake carrier

♦ Use new bolts!

Brake line to brake caliper 14 Nm

2.4 Repairing rear brake CII 38

Note

♦

Every time after changing pads, depress brake pedal firmly several times with vehicle stationary, so that brake pads are properly seated in their normal operating position.

♦

Use the brake filling and bleeding equipment -VAS 5234- or the extraction unit -V.A.G 1869/4- to draw off brake fluid from the brake fluid reservoir.

♦

Before removing a brake caliper or disconnecting a brake hose, fit brake pedal depressor -V.A.G 1869/2- (when doing this, release pressure in system).

35 Nm

Brake systems - Edition 05.2008

2. Repairing rear brake 89

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

1 - ABS speed sensor

❑ Before inserting sensor,

clean hole inner surface and coat with high-tem‐ perature paste G 052 112 A3.

2 - Hexagon socket head bolt, 8 Nm

3 - Multi-point socket head bolt, 90 Nm and turn 90° further

❑ Always renew after re‐

moving

4 - Wheel bearing housing

5 - Splash plate

6 - Torx bolt, 12 Nm

7 - Wheel bearing/hub unit

8 - Brake disc

❑ ∅ 286 mm ❑ Thickness: 12 mm ❑ Wear limit: 10 mm ❑ When worn, renew on

both sides of axle.

❑ Unscrew brake caliper

prior to removing.

9 - Cross-head screw, 4 Nm

10 - Bolt

❑ Front-wheel drive only

11 - Brake pads

❑ Thickness: 11 mm with‐

out backplate ❑ Pad wear limit: 2 mm without backplate ❑ Check thickness ⇒ Maintenance ; Booklet 18.1 . ❑ Always renew on both sides of an axle. ❑ Removing and installing ⇒ page 91

12 - Brake carrier with guide pin(s) and protective cap

❑ Supplied as genuine part, assembled with sufficient grease on guide pins. ❑ If protective caps or guide pins are damaged, install repair kit. Use lubricant sachet supplied to lubricate

guide pins.

13 - Pad retainer

❑ Always renew when changing pads.

14 - Brake caliper

❑ Do not disconnect brake hose when changing pads. ❑ Removing and installing ⇒ page 93 ❑ Repairing ⇒ page 124 ❑ Adjust handbrake cable first after repairing or replacement. ❑ Adjusting handbrake ⇒ page 101 .

90 Rep. Gr.46 - Brakes - mechanism

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

15 - Hose retainer

16 - Brake line, 14 Nm

17 - Self-locking hexagon bolt, 35 Nm

❑ Renew.

18 - Handbrake cable

❑ Adjusting handbrake ⇒ page 101 .

19 - Spring clip

20 - Brake hose

2.5 Removing and installing brake pads/lin‐

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

♦ Resetting and removal tool -T 10165-

ings

Brake systems - Edition 05.2008

2.5.1 Removing

Mark brake pads when removing if they are to be reused. Fit in

same position when installing, or braking will be uneven.

– Remove wheels.

2. Repairing rear brake 91

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

– Remove securing bolts from brake caliper, to do this counter‐

hold on guide pins.

– Remove brake caliper and secure with wire so that weight of

brake caliper does not strain or damage brake hose.

– Remove brake pads and pad retainers -arrows-.

Cleaning:

WARNING

Do not blow out brake system with compressed air; the result‐ ing dust constitutes a health hazard!

– Thoroughly clean contact surfaces for pad retainers (brake

pads) on brake carrier, and remove corrosion.

– Clean brake caliper.

Use only methylated spirits for cleaning the brake caliper housing.

2.5.2 Installing

Before pressing pistons back, draw off some brake fluid from res‐ ervoir with a bleeder bottle. Otherwise, particularly if reservoir has been topped up, fluid will overflow and cause damage.

– Screw in piston by turning knurled wheel of resetting and re‐

moval tool - T 10165 - clockwise, do not damage protective cap when doing this.

– To aid screwing in, use special tool T10165/1.

♦ If pistons are difficult to move, use a 13 mm open jaw spanner

on flats -arrow A- provided for this purpose.

92 Rep. Gr.46 - Brakes - mechanism

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

– Insert pad retainers -arrows- and brake pads into brake carrier.

– Ensure that brake pads are seated correctly in pad retainers

-arrows-.

– Secure brake caliper with new self-locking bolts.

♦ The repair kit includes four self-locking hexagon bolts which

must always be installed.

– Fit wheels.

Specified torque of wheel bolts ⇒ Running gear, axles, steering;

Rep. Gr. 44 ; Specified torques of wheel bolts .

♦

Every time after changing pads, depress brake pedal firmly several times with vehicle stationary, so that brake pads are properly seated in their normal operating position.

♦

Check brake fluid level after changing brake pads.

Specified torque: Hexagon bolt, brake caliper to brake carrier

♦ Use new bolts!

2.6 Removing and installing brake caliper

Special tools and workshop equipment required

Note

♦ Torque wrench -V.A.G 1331-

35 Nm

Brake systems - Edition 05.2008

2. Repairing rear brake 93

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

♦ Brake pedal depressor -V.A.G 1869/2-

2.6.1 Removing

This procedure applies only to exchanging or the following repair work on the brake caliper.

– Remove wheels.

– Unclip brake cable from lever on brake caliper.

– Pull spring clip downwards and pull handbrake cable out of

retainer on brake caliper.

– Connect bleeder bottle hose to brake caliper bleeder valve and

open bleeder valve.

– Apply brake pedal depressor -V.A.G 1869/2- .

– Close bleeder valve and remove bleeder bottle.

– Unscrew brake line.

– Remove both securing bolts from brake caliper; to do this,

counterhold on guide pin.

– Pull brake caliper off brake carrier.

2.6.2 Installing

• Piston is pressed back.

• The brake pads are seated in the retaining springs on the brake carrier.

– Secure brake caliper to brake carrier with new self-locking

bolts.

– Screw brake line to brake caliper.

– Bleed brake system ⇒ page 130 .

– Hook in handbrake cable and secure on retainer with spring

clip.

– Adjusting handbrake ⇒ page 101 .

– Fit wheels.

94 Rep. Gr.46 - Brakes - mechanism

Volkswagen Eos 2006 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

00 – Technical data

1 Brake allocation via PR No.

1.1 Front brakes, Touran

1.2 Front brakes, Golf

1.3 Front brakes, Eos

1.4 Rear brakes, Touran

1.5 Rear brakes, front-wheel drive Golf

1.6 Rear brakes, four-wheel drive Golf

1.7 Rear brakes, Eos

2 Technical data for brakes

2.1 Brake master cylinder and brake servo, Touran

2.2 Brake master cylinder and brake servo, Golf, Eos

2.3 Front brakes

2.4 Rear brakes (disc brakes)

3 Brake test

3.1 General

3.2 Test for vehicles with front-wheel drive

3.3.2 If no test rig is available for four-wheel drive vehicles, the brake test can also be carried out on a standard single-axle roller dynamometer as follows:

45 – Anti-lock brake system

1. General notes on anti-lock brake system 11

4.1 ABS Mark 70 (ABS/TCS)

4. Electrical/electronic components and fitting locations 15

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

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

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

5 Fault display via warning lamps

6.1 ABS Mark 70 (ABS/TCS)

6.1.2 Removing control unit and hydraulic unit

6.1.3 Unbolting control unit from hydraulic unit

6.1.4 Installing new control unit

6.1.5 Installing control unit and hydraulic unit

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

6.2.2 Removing control unit and hydraulic unit

6.2.3 Unbolting control unit from hydraulic unit

6.2.4 Installing new control unit

6.2.5 Installing control unit and hydraulic unit

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

6.3.2 Removing control unit and hydraulic unit

6.3.3 Unbolting control unit from hydraulic unit

6.3.4 Installing new control unit

6.3.5 Installing control unit and hydraulic unit

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

6.4.2 Removing control unit and hydraulic unit

6.4.3 Unbolting control unit from hydraulic unit

6.4.4 Installing new control unit

6.4.5 Installing control unit and hydraulic unit

7.1 Removing and installing parts of ABS system on front axle

7.1.1 Removing and installing speed sensor on front axle

7.2.1 Removing and installing speed sensor on rear axle

7.3.1 Removing and installing speed sensor on rear axle

8.1 Removing and installing ESP sensor unit -G419- (Touran)

8.2 Removing and installing ESP sensor unit -G419- (Golf, Eos)

8.3 Removing and installing steering angle sender -G85-

8.4 Removing and installing brake servo vacuum sender -G483-

46 – Brakes - mechanism

1 Repairing front brakes

1.2.1 Removing

1.2.2 Installing

1.3 Removing and installing brake caliper

1.3.1 Removing

1.3.2 Installing

1.5.1 Removing

1.5.2 Installing

1.6 Removing and installing brake caliper

1.6.1 Removing

1.6.2 Installing

1.8.1 Removing

1.8.2 Installing

1.9 Removing and installing brake caliper

1.9.1 Removing

1.9.2 Installing

2 Repairing rear brake

2.1 Repairing rear brake CI 38

2.2.1 Removing

2.2.2 Installing

2.3 Removing and installing brake caliper