Volkswagen Golf Variant 2007 User Manual

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Service

Workshop Manual

Golf Variant 2007 ➤ Jetta 2005 ➤

Brake systems

Edition 12.2009

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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Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

Contents

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

1 Brake allocation via PR number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 Front brakes, Jetta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Front brakes, Jetta, North America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.3 Front brakes, Jetta, Japan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.4 Front brakes, Bora, Mexico . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.5 Front brakes, Golf Variant model year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.6 Front brakes, Golf Variant from model year 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.7 Front brakes, Jetta SportWagen as of model year 2008 (USA) . . . . . . . . . . . . . . . . . . . . . . 3

1.8 Rear brakes, Jetta up to week 50/2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.9 Rear brakes, Jetta as of week 50/2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.10 Rear brakes, Jetta, North America, up to week 50/2009 . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.11 Rear brakes, Jetta, North America, as of week 50/2009 . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.12 Rear brakes, Bora, Mexico, up to week 50/2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.13 Rear brakes, Bora, Mexico, as of week 50/2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.14 Rear brakes, Jetta, Japan, up to week 50/2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.15 Rear brakes, Jetta, Japan, as of week 50/2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.16 Rear brakes, Golf Variant from model year 2008 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.17 Rear brakes, Golf Variant from model year 2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.18 Rear brakes, Jetta SportWagen as of model year 2009 (USA) . . . . . . . . . . . . . . . . . . . . . . 5

2 Technical data for brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.1 Brake master cylinder and brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.2 Front brakes FS III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.3 Front brakes FN 3 (15”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.4 Front brakes FN 3 (16”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.5 Rear brakes C 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.6 Rear brakes CII 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.7 Rear brake CII 41 (15") . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.8 Rear brake CII 41 (16") . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.9 Rear brakes, Bosch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1 General notes on anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2 Notes for repair work on anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3 Connecting VAS 5051 and selecting functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

4 Electrical/electronic components and locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.1 ABS Mark 70 (ABS/TCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.2 ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 27/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.3 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 27/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5 Fault display via warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.1 ABS/TCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.2 ABS/EDL/TCS/ESP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6 ABS Mark 70 (ABS/TCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6.1 Connecting brake lines from tandem brake master cylinder to hydraulic unit, left-hand drive

vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6.2 Connecting brake lines from tandem brake master cylinder to hydraulic unit, right-hand drive

vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6.3 Removing control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Contents i

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

6.4 Unbolting control unit from hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6.5 Installing new control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6.6 Installing control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

7 ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 27/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . 34

7.1 Connecting brake lines from brake master cylinder to hydraulic unit, left-hand drive vehicle

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

7.2 Connecting brake lines from tandem brake master cylinder to hydraulic unit, right-hand drive

vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

7.3 Removing control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

7.4 Unbolting control unit from hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

7.5 Installing new control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

7.6 Installing control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

8 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 27/2008 . . . . . . . . . . . . . . . . . . . . . . . . . . 43

8.1 Connecting brake lines from brake master cylinder to hydraulic unit, left-hand drive vehicle

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

8.2 Connecting brake lines from tandem brake master cylinder to hydraulic unit, right-hand drive

vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

8.3 Removing control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

8.4 Unbolting control unit from hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

8.5 Installing new control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

8.6 Installing control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

9 Removing and installing parts of ABS system on front and rear axle . . . . . . . . . . . . . . . . 53

9.1 Removing and installing parts of ABS system on front axle . . . . . . . . . . . . . . . . . . . . . . . . 53

9.2 Removing and installing parts of anti-lock brake system on rear axle (front-wheel drive) . . 54

9.3 Removing and installing parts of anti-lock brake system on rear axle (four-wheel drive) . . 55

10 Removing and installing parts of ESP system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

10.1 Removing and installing ESP sensor unit G419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

10.2 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

10.3 Removing and installing brake servo vacuum sender G483 . . . . . . . . . . . . . . . . . . . . . . . . 58

46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

1 Repairing front brakes, FS III brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

1.1 Removing and installing brake pads, brake caliper FS III . . . . . . . . . . . . . . . . . . . . . . . . . . 61

1.2 Removing and installing brake caliper, FS III brake caliper . . . . . . . . . . . . . . . . . . . . . . . . 64

2 Repairing front brakes, FN 3 brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

2.1 Removing and installing brake pads, brake caliper FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . 70

2.2 Removing and installing brake caliper, FS III brake caliper . . . . . . . . . . . . . . . . . . . . . . . . 73

3 Repairing rear brake C 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

3.1 Removing and installing brake pads for C 38 brake caliper . . . . . . . . . . . . . . . . . . . . . . . . 76

3.2 Removing and installing brake caliper C 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

4 Repairing rear brakes CII 38/CII 41 (front-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

4.1 Removing and installing brake pads for C 38 brake caliper . . . . . . . . . . . . . . . . . . . . . . . . 82

4.2 Removing and installing brake caliper CII 38/CII 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

5 Repairing rear brake CII 41 (four-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

5.1 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

5.2 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

6 Repairing rear brakes, Bosch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

6.1 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

6.2 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

7 Adjusting handbrake up to week 50/2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

8 Adjusting handbrake as of week 50/2009 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

9 Assembly overview - handbrake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

9.1 Removing and installing handbrake cable up to model year 2007 . . . . . . . . . . . . . . . . . . . . 103

9.2 Removing and installing handbrake cable from model year 2008 . . . . . . . . . . . . . . . . . . . . 106

ii Contents

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Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

10 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

10.1 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

10.2 Clipping brake pedal to brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

10.3 Brake light switch F up to week 50/05 (left-hand drive vehicles) . . . . . . . . . . . . . . . . . . . . 111

10.4 New version of brake light switch (left-hand drive vehicles) . . . . . . . . . . . . . . . . . . . . . . . . 112

10.5 Brake light switch (right-hand drive vehicles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

1 Repairing front FS III brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

1.1 Removing and installing piston for brake caliper FS III . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

2 Repairing front FN 3 brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

2.1 Removing and installing piston for brake caliper FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

3 Repairing rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

3.1 Repairing brake caliper C 38/CII 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

3.2 Repairing CII 41 brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

3.3 Removing brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

3.4 Installing brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

3.5 Pre-bleeding brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

4 Repairing Bosch rear brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

4.1 Removing and installing brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

4.2 Pre-bleeding brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

5 Pressurised leak test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

5.1 Test prerequisites: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

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

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

6.1 Pre-bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

6.2 Bleeding (normal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

6.3 Subsequent bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

6.4 Changing brake fluid (every 2 years) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

7 Brake servo and master brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

7.1 Assembly overview - brake servo/brake master cylinder (left-hand drive vehicle) . . . . . . . . 134

7.2 Assembly overview - brake servo/brake master cylinder (right-hand drive vehicle) . . . . . . 136

7.3 Overview - vacuum pump for brake servo (diesel vehicles) . . . . . . . . . . . . . . . . . . . . . . . . 137

7.4 Checking non-return valve : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

7.5 Removing and installing brake servo pressure sensor G294 . . . . . . . . . . . . . . . . . . . . . . 138

7.6 Vacuum pump for brakes V192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

7.7 Removing and installing brake light switch F as of week 50/05 . . . . . . . . . . . . . . . . . . . . . . 139

8 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

9 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

9.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

9.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

10 Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

10.1 Assembly overview - flanging tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

10.2 Work instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Contents iii

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

iv Contents

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00 – Technical data

1 Brake allocation via PR number

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 1ZE front brake -arrow- is installed in the ve‐ hicle.

Note

The PR number of the rear brake is not on the vehicle data sticker. To find information about the rear brake, please search in ELSA/ Vehicle-specific notes.

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

♦ Allocation ⇒ Electronic Parts Catalogue “ETKA” .

♦ The following tables explain the PR numbers. These are im‐

portant for the brake caliper/brake disc and brake pads.

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

1.1 Front brakes, Jetta

Engine PR number Front brakes

1.6 l - 75 kW 1ZM FS III (15”)

1.6 l - 85 kW

1.9 l - 77 kW TDI unit injector

1.4 l - 90 kW 1ZE FN 3 (15”)

1.4 l - 103 kW

2.0 l - 100 kW TDI

2.0 l - 103 kW TDI

2.0 l - 110 kW FSI

1.4 l - 125 kW 1LJ FN 3 (16”)

2.0 l - 125 kW TDI

2.0 l - 147 kW T-FSI

1.2 Front brakes, Jetta, North America

Engine PR number Front brakes

1.9 l - 74 kW TDI unit injector

2.5 l - 110 kW

2.5 l - 125 kW

2.0 l - 103 kW TDI 1ZD / 1LV FN 3 (16”)

2.0 l - 147 kW T-FSI

1ZP FN 3 (15”)

1.3 Front brakes, Jetta, Japan

Engine PR number Front brakes

1.4 l - 90 kW 1ZP FN 3 (15”)

1. Brake allocation via PR number 1

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

Engine PR number Front brakes

2.0 l - 110 kW FSI

2.0 l - 125 kW TDI 1ZD FN 3 (16”)

2.5 l - 125 kW 1ZP FN 3 (15”)

1.4 l - 125 kW 1ZD FN 3 (16”)

2.0 l - 147 kW T-FSI 1ZD / 1LV FN 3 (16”)

1.4 Front brakes, Bora, Mexico

Engine PR number Front brakes

2.5 l - 110 kW 1ZE FN 3 (15”)

2.5 l - 125 kW

2.0 l - 147 kW T-FSI 1ZD / 1LL FN 3 (16”)

1.5 Front brakes, Golf Variant model year 2008

Engine PR number Front brakes

1.4 l - 59 kW 1ZM FS III (15”)

1.6 l - 75 kW

1.9 l - 77 kW TDI unit injector, front-wheel drive

1.4 l - 90 kW 1ZE FN 3 (15”)

1.4 l - 103 kW

2.0 l - 100 kW TDI

2.0 l - 103 kW TDI

1.9 l - 77 kW TDI unit injector, 4Motion

1.4 l - 125 kW

2.0 l - 147 kW T-FSI

1.6 Front brakes, Golf Variant from model year 2009

Engine PR number Front brakes

1.4 l - 59 kW 1ZM FS III (15”)

1.6 l - 75 kW

1.9 l - 77 kW TDI unit injector, front-wheel drive

1LJ FN 3 (16”)

1.4 l - 90 kW 1ZE FN 3 (15”)

1.4 l - 103 kW

2.0 l - 100 kW TDI 1LJ FN 3 (16”)

2.0 l - 103 kW TDI

2.0 l - 125 kW TDI

1.9 l - 77 kW TDI unit injector, 4Motion

1.4 l - 118 kW

1.4 l - 125 kW

2.0 l - 147 kW T-FSI

2 Rep. Gr.00 - Technical data

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1.7 Front brakes, Jetta SportWagen as of model year 2008 (USA)

Engine PR number Front brakes

2.5 l/125 kW 1ZP FN 3 (15”)

2.0 l 103 kW TDI 1ZD / 1LV FN 3 (16”)

2.0 l - 147 kW T-FSI

1.8 Rear brakes, Jetta up to week 50/2009

Engine PR number Rear brakes

1.6 l - 75 kW 1KF CII 41 (15")

1.6 l - 85 kW

1.9 l - 77 kW TDI unit injector

1.4 l - 90 kW

1.4 l - 103 kW

2.0 l - 100 kW TDI

2.0 l - 103 kW TDI

2.0 l - 110 kW FSI

1.4 l - 125 kW 1KJ CII 41 (16")

2.0 l - 125 kW TDI

2.0 l - 147 kW T-FSI

1.9 Rear brakes, Jetta as of week 50/2009

Engine PR number Rear brakes

1.6l - 75 kW 1KT Bosch

1.6l - 85 kW

1.9 l - 77 kW TDI unit injector

1.4l - 90 kW

1.4l - 103 kW

2.0l - 100 kW TDI

2.0l - 103 kW TDI

2.0l - 110 kW FSI

1.4l - 125 kW

2.0l - 125 kW TDI

2.0l - 147 kW T-FSI

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

1.10 Rear brakes, Jetta, North America, up to week 50/2009

Engine PR number Rear brakes

1.9 l - 74 kW TDI unit injector

2.0l - 103 kW TDI

2.5l - 110 kW

2.5l - 125 kW

2.0 l - 147 kW T-FSI Sport

2.0 l - 103 kW TDI Sport 1KV CII 38 (16")

1KE CII 41 (15")

1KJ CII 41 (16")

1. Brake allocation via PR number 3

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

Engine PR number Rear brakes

2.0l - 147 kW T-FSI Jet‐

1KY / 1KV CII 38 (16")

ta GLI only

1.11 Rear brakes, Jetta, North America, as of week 50/2009

Engine PR number Rear brakes

1.9 l - 74 kW TDI unit injector

2.0 l - 103 kW TDI

2.5 l - 110 kW

2.5 l - 125 kW

2.0l - 147 kW T-FSI Sport

2.0l - 103 kW TDI Sport

2.0 l - 147 kW T-FSI Jetta GLI only

1.12 Rear brakes, Bora, Mexico, up to week 50/2009

Engine PR number Rear brakes

2.5 l - 110 kW 1KD C 38 (15”)

2.5 l - 125 kW 1KF CII 41 (15")

2.0 l - 147 kW T-FSI 1KY CII 41 (16")

1.13 Rear brakes, Bora, Mexico, as of week

1KS Bosch

50/2009

Engine PR number Rear brakes

2.5l - 110 kW 1KD C 38 (15”)

2.5l - 125 kW 1KS Bosch

2.0l - 147 kW T-FSI

1.14 Rear brakes, Jetta, Japan, up to week 50/2009

Engine PR number Rear brakes

1.4 l - 90 kW 1KE CII 41 (15")

2.0 l - 110 kW FSI

2.0 l - 125 kW TDI

2.5 l - 125 kW

1.4 l - 125 kW

2.0 l - 147 kW T-FSI Sport

2.0l - 147 kW T-FSI GLI 1KV CII 38 (16")

1.15 Rear brakes, Jetta, Japan, as of week 50/2009

Engine PR number Rear brakes

1.4l - 90 kW 1KS Bosch

4 Rep. Gr.00 - Technical data

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Engine PR number Rear brakes

2.0l - 110 kW FSI

2.0l - 125 kW TDI

2.5l - 125 kW

1.4l - 125 kW

2.0l - 147 kW T-FSI Sport

2.0l - 147 kW T-FSI GLI

1.16 Rear brakes, Golf Variant from model year 2008

Engine PR number Rear brakes

1.4 l - 59 kW 1KF CII 41 (15")

1.6 l - 75 kW

1.9 l - 77 kW TDI unit injector front-wheel drive and 4Motion

1.4 l - 90 kW

1.4 l - 103 kW

2.0 l - 100 kW TDI

2.0 l - 103 kW TDI

1.4 l - 125 kW 1KJ CII 41 (16")

2.0 l - 147 kW T-FSI

1.17 Rear brakes, Golf Variant from model

Engine PR number Rear brakes

1.4 l - 59 kW 1KF CII 41 (15")

1.6 l - 75 kW

1.9 l - 77 kW TDI unit injector front-wheel drive and 4Motion

1.4 l - 90 kW

year 2009

1.4 l - 103 kW

2.0 l - 100 kW TDI 1KJ CII 41 (16")

2.0 l - 103 kW TDI

2.0 l - 125 kW TDI

1.4 l - 118 kW

1.4 l - 125 kW

2.0 l - 147 kW T-FSI

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

1.18 Rear brakes, Jetta SportWagen as of model year 2009 (USA)

Engine PR number Rear brakes

2.5 l/125 kW 1KE CII 41 (15")

2.0 l 103 kW TDI 1KJ CII 41 (16")

2.0 l - 147 kW T-FSI

1. Brake allocation via PR number 5

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

2 Technical data for brakes

2.1 Brake master cylinder and brake servo

1.4 l - 59 kW; 1.6 l - 75 kW; 1.6 l - 85 kW; 1.9 l - 77 kW TDI unit injector front-wheel drive; 1.9 l - 74 kW TDI unit injector; 1.4 l - 90 kW; 2.5 l - 110 kW

Brake master cylinder ∅ in mm 22.2 Brake servo (LHD) ∅ in inches 10 Brake servo (RHD) ∅ in inches 7/8

1.9l - 77 kW TDI unit injector 4Motion; 1.4l - 118 kW; 1.4l - 125 kW; 2.0l - 125 kW TDI; 2.0l - 147 kW T-FSI; 2.5l - 125 kW; 1.4l 103 kW; 2.0l - 100 kW TDI; 2.0l - 103 kW TDI; 2.0l - 110 kW FSI

Brake master cylinder ∅ in mm 23.8 Brake servo (LHD) ∅ in inches 10 Brake servo (RHD) ∅ in inches 7/8

2.2 Front brakes FS III

Item PR number

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

thickness with‐ out backplate

3 Brake disc ∅ in

Brake disc, thickness

4 Brake caliper

piston

mm 14

mm mm 22

∅ in

mm

2.3 Front brakes FN 3 (15”)

Item PR number

1ZM / 1ZF

1ZE / 1ZP

280

54

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

mm 14 thickness with‐ out backplate

3 Brake disc ∅ in

288

mm Brake disc,

mm 25 thickness

4 Brake caliper

piston

∅ in

mm

54

6 Rep. Gr.00 - Technical data

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2.4 Front brakes FN 3 (16”)

Item PR number

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

thickness with‐ out backplate

3 Brake disc ∅ in

Brake disc, thickness

4 Brake caliper

piston

2.5 Rear brakes C 38

Item PR number

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

thickness with‐

1LL / 1ZD / 1LV / 1LJ

mm 14

mm mm 25

∅ in

mm

mm 11

out backplate

3 Brake disc ∅ in

mm

Brake disc,

mm 10

thickness

4 Brake caliper

piston

∅ in

mm

312

54

1KD

255

38

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

2.6 Rear brakes CII 38

Item PR number

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

thickness with‐ out backplate

3 Brake disc ∅ in

Brake disc, thickness

4 Brake caliper

piston

1KY / 1KV

mm 11

mm mm 12

∅ in

mm

286

38

2. Technical data for brakes 7

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

2.7 Rear brake CII 41 (15")

Item PR number

1KE / 1KF

1 Brake caliper CII 41 (15") 2 Brake pad,

mm 11 thickness with‐ out backplate

3 Brake disc ∅ in

260

mm Brake disc,

mm 12 thickness

4 Brake caliper

piston

2.8 Rear brake CII 41 (16")

Item PR number

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

thickness with‐ out backplate

3 Brake disc ∅ in

Brake disc, thickness

4 Brake caliper

piston

2.9 Rear brakes, Bosch

Item PR number

1 Brake caliper Bosch 2 Brake pad,

thickness with‐

∅ in

mm

mm 11

mm

mm 12

∅ in

mm

mm 12

1KJ

286

1KT / 1KS

out backplate

3 Brake disc ∅ in

272

mm Brake disc,

mm 10 thickness

4 Brake caliper

piston

∅ in

mm

41

38

8 Rep. Gr.00 - Technical data

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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.

The brake control 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

Note

Golf Variant 2007 ➤ , Jetta 2005 ➤

via a Haldex coupling

Brake systems - Edition 12.2009

The brake test should be performed on a single-axle roller dyna‐ mometer with contra-rotating rollers for four-wheel drive vehicles.

Contra-rotating means that the dynamometer rollers are driven 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.

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 dy‐ namometer as follows:

– 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.

– 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.

3. Brake test 9

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

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.

Models with ABS Mark 60 do not have a mechanical brake pres‐ sure 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 -K47- comes on, the rear wheels may lock prematurely.

ABS layout in left-hand drive vehicle.

1 - Hydraulic unit and control unit

2 - Brake servo

ABS layout in a right-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.

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

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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 131 .

♦ 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 131 .

♦ 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. ( Sealing plugs -1H0 698 311 A- must be used).

♦ 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.

♦ 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.

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

2. Notes for repair work on anti-lock brake system 11

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

3 Connecting -VAS 5051- and select‐

ing functions

Special tools and workshop equipment required

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

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 vehicle diagnosis, testing and information system -VAS 5051- -1- as follows:

– Connect connector of diagnosis cable -2- to diagnostic con‐

nection.

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

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– Switch on vehicle diagnostic, testing and information system

-VAS 5051B- -arrow-.

The vehicle diagnosis, testing and information system -VAS 5051- is ready for operation when the selector buttons for the op‐ erating 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 the vehicle diagnosis, testing and information system VAS 5051- has read all control units in the vehicle.

– Press > .

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

– 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.

3. Connecting VAS 5051 and selecting functions 13

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

4 Electrical/electronic components and

locations

4.1 ABS Mark 70 (ABS/TCS)

1 - ABS control unit -J104-

❑ Location: on the hy‐

draulic unit on right in engine compartment.

❑ Can be tested in “Gui‐

ded fault finding” using VAS 5051-

❑ Do not separate con‐

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

❑ Removing and installing

⇒ page 29 .

2 - ABS hydraulic unit -N55-

❑ Location: on right in en‐

gine compartment.

The hydraulic unit consists of the components:

V64-

❑ ABS hydraulic pump -

❑ Can be tested in “Gui‐

ded fault finding” using VAS 5051-

❑ Valve block (contains in‐

let and outlet valves).

❑ ABS hydraulic pump -

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

❑ Removing and installing

⇒ page 29 .

3 - Brake pad warning lamp K32-

❑ Location: in dash panel insert ❑ Function: ⇒ page 20 .

4 - ABS warning lamp -K47-

❑ Location: in dash panel insert ❑ Function: ⇒ page 20 .

5 - Traction control system warning lamp -K86-

❑ Location: in dash panel insert ❑ Function: ⇒ page 20 .

6 - Brake system warning lamp -K118-

❑ Location: in dash panel insert ❑ Function: ⇒ page 20 .

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

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7 - Brake light switch -F- up to week 50/2005

❑ Including brake pedal switch -F47- . ❑ Location: on brake pedal. ❑ Removing, installing and adjusting ⇒ page 111 .

8 - Brake light switch -F- from week 50/2005

❑ Including brake pedal switch -F47- . ❑ Location: on brake master cylinder. ❑ Removing and installing ⇒ page 139 .

9 - TCS and ESP button -E256-

❑ Location: in centre console.

10 - Diagnostic connection

❑ Location: driver side footwell cover.

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

❑ Can be tested in “Guided fault finding” using -VAS 5051❑ Removing and installing ⇒ page 53 .

12 - Wheel bearing housing

13 - Wheel bearing/hub unit

❑ ABS sensor ring is installed in wheel bearing.

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

❑ Can be tested in “Guided fault finding” using -VAS 5051❑ Removing and installing ⇒ page 54 .

15 - Rear axle assembly with stub axle

16 - Wheel hub with wheel bearing

❑ ABS sensor ring is installed in wheel bearing.

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

4. Electrical/electronic components and locations 15

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

4.2 ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 27/2008

1 - ABS control unit -J104-

❑ Location: on the hy‐

draulic unit on right in engine compartment.

❑ Do not separate con‐

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

❑ Removing and installing

⇒ page 38 .

2 - ABS hydraulic unit -N55-

❑ Location: on right in en‐

gine 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 38 .

3 - Brake pad warning lamp K32-

❑ Location: in dash panel

insert

❑ Function: ⇒ page 20 .

4 - ABS warning lamp -K47-

❑ Location: in dash panel insert ❑ Function: ⇒ page 20 .

5 - ESP and TCS warning lamp -K155-

❑ Only vehicles with ABS/EDL/TCS/ESP. ❑ Location: in dash panel insert ❑ Function: ⇒ page 20 .

6 - Brake system warning lamp -K118-

❑ Location: in dash panel insert ❑ Function: ⇒ page 20 .

7 - Brake light switch -F- up to week 50/2005

❑ Including brake pedal switch -F47- . ❑ Location: on brake pedal. ❑ Removing and installing ⇒ page 111 .

8 - Brake light switch -F- from week 50/2005

❑ Including brake pedal switch -F47- . ❑ Location: on brake master cylinder.

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

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Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

❑ Removing and installing ⇒ page 139 .

9 - TCS and ESP button -E256-

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

10 - ESP sensor unit -G419-

❑ Only vehicles with ABS/EDL/TCS/ESP. ❑ Location: 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 ⇒ page 57 .

11 - Diagnostic connection

❑ Location: driver side footwell cover.

12 - Steering angle sender -G85-

❑ Location: on steering column between steering wheel and steering column switch. ❑ Removing and installing ⇒ page 58 .

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

❑ Removing and installing ⇒ page 53 .

14 - Wheel bearing housing

15 - Wheel bearing/hub unit

❑ ABS sensor ring is installed in wheel bearing.

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

Figure for front-wheel drive

❑ Removing and installing (front-wheel drive) ⇒ page 54 ❑ Removing and installing (four-wheel drive) ⇒ page 55

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 wheel bearing.

4. Electrical/electronic components and locations 17

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

4.3 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 27/2008

1 - ABS control unit -J104-

❑ Location: on the hy‐

draulic unit on right in engine compartment.

❑ Do not separate con‐

nector before success‐ fully completing self-di‐ agnosis. Switch ignition off before separating 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 46 .

2 - ABS hydraulic unit -N55-

❑ Location: on right in en‐

gine 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 46 .

3 - Brake pad warning lamp -K32-

❑ Location: in dash panel insert ❑ Function: ⇒ page 20 .

4 - ABS warning lamp -K47-

❑ Location: in dash panel insert ❑ Function: ⇒ page 20 .

5 - ESP and TCS warning lamp -K155-

❑ Only vehicles with ABS/EDL/TCS/ESP. ❑ Location: in dash panel insert ❑ Function: ⇒ page 20 .

6 - Brake system warning lamp -K118-

❑ Location: in dash panel insert ❑ Function: ⇒ page 20 .

7 - Brake light switch -F-

❑ Including brake pedal switch -F47- .

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

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Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

❑ Location: on brake master cylinder. ❑ Removing and installing ⇒ page 139 .

8 - TCS and ESP button -E256-

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

9 - Diagnostic connection

❑ Location: driver side footwell cover.

10 - Steering angle sender -G85-

Note

❑ Location A: on steering column between steering wheel and steering column switch. ❑ Removing and installing ⇒ page 58 . ❑ Location B: in steering box.

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

❑ Removing and installing ⇒ page 53 .

12 - Wheel bearing/hub unit

❑ ABS sensor ring is installed in wheel bearing.

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

Figure for front-wheel drive

❑ Removing and installing (front-wheel drive) ⇒ page 54 ❑ Removing and installing (four-wheel drive) ⇒ page 55

14 - Wheel bearing/hub unit

Figure for front-wheel drive

❑ ABS sensor ring is installed in wheel bearing.

4. Electrical/electronic components and locations 19

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

5 Fault display via warning lamps

5.1 ABS/TCS

Warning lamps

Item Description

1 Traction control system warning lamp -K862 Brake pad warning lamp -K323 ABS warning lamp -K474 Brake system warning lamp -K118-

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

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Warning lamps in vehicles for the USA

Item Description

1 Traction control system warning lamp -K862 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 wire 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 the

ignition has been switched on and test sequence has been completed, 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 with EDL -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.

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

5. Fault display via warning lamps 21

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

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 ⇒ Ve‐ hicle diagnosis, testing and information system VAS 5051 Inter‐ rogate fault memory.

-a- Short-circuit to positive in TCS and ESP 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 in operation.

♦ 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 ⇒ Vehicle diagnosis, testing and information system VAS 5051 Perform electrical check.

5.2 ABS/EDL/TCS/ESP

Warning lamps

Item Description

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

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

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Warning lamps in vehicles for the USA

Item Description

1 ESP 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 fault in the line⇒ 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 the

ignition has been switched on and test sequence has been completed, 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.

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

-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 with EDL con‐ trol 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.

5. Fault display via warning lamps 23

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

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.

ESP warning lamp -K155-

♦ If the stabilisation program warning lamp -K155- -1- does not

go out after switching ignition on and completion of test se‐ quence 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 ⇒ Vehicle diagnosis, testing and information system VAS 5051 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 warning lamp -K155- flashes while the vehicle is in motion, the TCS or ESP is in operation.

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

the self test, the fault may be:

-a- The ESP warning lamp -K155- is defective⇒ Vehicle diagno‐ sis, testing and information system VAS 5051 Perform electrical check.

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

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6 ABS Mark 70 (ABS/TCS)

1 - ABS control unit -J104-

❑ Removing and installing

⇒ page 29 .

2 - ABS hydraulic unit -N55-

❑ Removing and installing

⇒ page 29 .

3 - Brake line

❑ 14 Nm ❑ From primary piston cir‐

cuit of brake master cyl‐

inder to hydraulic unit ❑ Identification: union nut

with thread M10 x 1 or

M12 x 1

During production the thread was changed from M10 x 1 to M12 x 1.

4 - Brake line

WARNING

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

❑ 14 Nm ❑ From secondary piston

circuit of brake master

cylinder to hydraulic unit ❑ Identification: union nut

with thread M12 x 1

5 - Brake line

❑ 14 Nm ❑ To front left brake cali‐

per ❑ Identification: union nut

with thread M12 x 1 or

M10 x 1

WARNING

During production the thread was changed from M12 x 1 to M10 x 1.

6 - Brake line

❑ 14 Nm ❑ To front right brake caliper ❑ Identification: union nut with thread M10 x 1 or M12 x 1

WARNING

During production the thread was changed from M10 x 1 to M12 x 1.

6. ABS Mark 70 (ABS/TCS) 25

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

7 - Brake line

❑ 14 Nm ❑ To rear left brake caliper ❑ Identification: union nut with thread M12 x 1

8 - Brake line

❑ 14 Nm ❑ To rear right brake caliper ❑ Identification: union nut with thread M10 x 1

9 - Torx 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 vacuum pump to create the required vacuum ⇒ page 137 . ❑ Functional check:

– Depress brake pedal forcefully several times with engine switched off. Vacuum in unit is dissipated as a

result.

– 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 as a complete unit. ❑ Removing and installing ⇒ page 144 .

14 - Sealing ring

15 - Tandem brake master cylinder

❑ Cannot be repaired. If faulty, renew as a complete unit. ❑ Removing and installing ⇒ page 141 .

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-

❑ In vehicles with an FSI engine without HBV (hydraulic brake with vacuum servo) ❑ Removing and installing ⇒ page 138 .

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

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6.1 Connecting brake lines from tandem brake master cylinder to hydraulic unit, left-hand drive vehicle

On tandem brake master cylinder:

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

- Identification: union nut with thread M10 x 1

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

- Identification: union nut with thread M12 x 1

1 - From hydraulic unit to front left brake caliper.

3 - From hydraulic unit to rear right brake caliper.

4 - From hydraulic unit to rear left brake caliper.

On hydraulic unit:

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

- Identification: union nut with thread M10 x 1 or M12 x 1.

During production the thread was changed from M10 x 1 to

WARNING

M12 x 1.

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

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

- Identification: union nut with thread M12 x 1

1 - From hydraulic unit to front left brake caliper.

- Identification: union nut with thread M12 x 1 or M10 x 1

WARNING

During production the thread was changed from M12 x 1 to M10 x 1.

2 - From hydraulic unit to front right brake caliper.

- Identification: union nut with thread M10 x 1 or M12 x 1

WARNING

During production the thread was changed from M10 x 1 to M12 x 1.

3 - From hydraulic unit to rear right brake caliper.

- Identification: union nut with thread M10 x 1

4 - From hydraulic unit to rear left brake caliper.

- Identification: union nut with thread M12 x 1

6. ABS Mark 70 (ABS/TCS) 27

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

6.2 Connecting brake lines from tandem brake master cylinder to hydraulic unit, right-hand drive vehicle

On tandem brake master cylinder:

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

- Identification: union nut with thread M10 x 1

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

- Identification: union nut with thread M12 x 1

1 - From hydraulic unit to front right brake caliper.

On hydraulic unit:

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

- Identification: union nut with thread M10 x 1 or M12 x 1.

WARNING

During production the thread was changed from M10 x 1 to M12 x 1.

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

- Identification: union nut with thread M12 x 1

1 - From hydraulic unit to front left brake caliper.

- Identification: union nut with thread M12 x 1 or M10 x 1

WARNING

During production the thread was changed from M12 x 1 to M10 x 1.

2 - From hydraulic unit to front right brake caliper.

- Identification: union nut with thread M10 x 1 or M12 x 1

WARNING

During production the thread was changed from M10 x 1 to M12 x 1.

3 - From hydraulic unit to rear right brake caliper.

- Identification: union nut with thread M10 x 1

4 - From hydraulic unit to rear left brake caliper.

- Identification: union nut with thread M12 x 1

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

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6.3 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-

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

6. ABS Mark 70 (ABS/TCS) 29

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

Sealing plug -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 - M10 sealing plugs

3 - M12 sealing plugs

Removing

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.

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

– 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-cyl. diesel en‐

gine (2-valve); Rep. Gr. 23 ; Mixture preparation, injection .

2.0 l diesel engine:

– Remove connecting pipe between intake hose and turbo‐

charger.

– Remove toothed belt guard upper part.

Continuation for all models:

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

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

pull off in -direction of arrow 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 sealing

plugs -1H0 698 311 A- .

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

seal.

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

– Pull hydraulic unit with control unit in -direction of arrow- up‐

wards out of dampers.

6.4 Unbolting control unit from hydraulic unit

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

– Remove Torx bolts -arrows-.

level surface.

6. ABS Mark 70 (ABS/TCS) 31

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

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

-direction of arrow-.

– Carefully pull all seals from hydraulic unit contact pins.

WARNING

♦ Printed circuit board becomes visible when control unit is

removed.

♦ No moisture or particles of dirt may enter 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.

6.5 Installing new control unit

WARNING

Severe shocks (e.g. dropping, impact) may destroy control unit. 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

bolts.

Note

♦

It is not possible to fit a new control unit more than twice to an installed hydraulic unit to ensure that the flexible seal is free of leaks.

♦

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

6.6 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.

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

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Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

– Install in reverse order.

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

– Bleed brake system ⇒ page 131 .

– Connect battery ⇒ Electrical system; Rep. Gr. 27 ; Battery;

Disconnecting and reconnecting battery .

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

and information system VAS 5051 in ”Guided fault finding”.

Specified torques

Component Specified torque

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 M10 x 1 14 Nm Thread M12 x 1 14 Nm

6. ABS Mark 70 (ABS/TCS) 33

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

7 ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 27/2008

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 38 .

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 38 .

3 - Brake line

❑ 14 Nm ❑ From primary piston cir‐

cuit of brake master cyl‐ inder to hydraulic unit

❑ Identification: ∅ 6.5 mm

and union nut with long thread M 12 x 1.

4 - Brake line

❑ 14 Nm ❑ From secondary piston

circuit of brake master cylinder to hydraulic unit

❑ Identification: ∅ 6.5 mm

and union nut with long thread M 12 x 1.

5 - Brake line

❑ 14 Nm ❑ To front left brake cali‐

per

❑ Identification: ∅ 5.25 mm and union nut with short thread M12 x 1.

6 - Brake line

❑ 14 Nm ❑ To front right brake caliper ❑ Identification: ∅ 5.25 mm and union nut with thread M10 x 1

7 - Brake line

❑ 14 Nm ❑ To rear left brake caliper ❑ Identification: ∅ 5.25 mm and union nut with short thread M12 x 1.

8 - Brake line

❑ 14 Nm ❑ To rear right brake caliper ❑ Identification: ∅ 5.25 mm and union nut with thread M10 x 1

9 - Torx socket head bolt, 5.5 Nm

❑ Use new bolts.

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

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Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

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. ❑ Some vehicles with a petrol engine and an automatic gearbox are equipped with a brake vacuum pump

⇒ page 138 .

❑ A vacuum sender is fitted in vehicles with HBV ⇒ page 58 . ❑ Diesel engines are fitted with a vacuum pump to create the required vacuum ⇒ page 137 . ❑ 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 144 .

14 - Sealing ring

15 - Brake servo vacuum sender -G483-

❑ Only on vehicles having HBV ❑ Removing and installing ⇒ page 58 .

16 - Brake master cylinder

❑ Allocation ⇒ Electronic Parts Catalogue (ETKA) . ❑ Cannot be repaired. If faulty, renew as a complete unit. ❑ Removing and installing ⇒ page 141 .

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

7. ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 27/2008 35

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

7.1 Connecting brake lines from brake mas‐ ter cylinder to hydraulic unit, left-hand drive vehicle

On brake master cylinder:

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

- Identification: ∅ 6.5 mm and union nut with thread M12 x 1

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

- Identification: ∅ 6.5 mm and union nut with thread M12 x 1

1 - From hydraulic unit to front left brake caliper.

3 - From hydraulic unit to rear right brake caliper.

4 - From 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 long thread M 12 x

1.

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

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

1.

1 - From hydraulic unit to front left brake caliper.

- Identification: ∅ 5.25 mm and union nut with short thread M12

x 1.

2 - From hydraulic unit to front right brake caliper.

- Identification: ∅ 5.25 mm and union nut with thread M10 x 1

3 - From hydraulic unit to rear right brake caliper.

- Identification: ∅ 5.25 mm and union nut with thread M10 x 1

4 - From hydraulic unit to rear left brake caliper.

- Identification: ∅ 5.25 mm and union nut with short thread M12

x 1.

7.2 Connecting brake lines from tandem brake master cylinder to hydraulic unit, right-hand drive vehicle

On tandem brake master cylinder:

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

- Identification: ∅ 6.5 mm and union nut with thread M12 x 1

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

- Identification: ∅ 6.5 mm and union nut with thread M12 x 1

1 - From hydraulic unit to front right brake caliper.

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

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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 12 x

1.

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

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

1.

1 - From hydraulic unit to front left brake caliper.

- Identification: ∅ 5.25 mm and union nut with short thread M12 x 1.

2 - From hydraulic unit to front right brake caliper.

- Identification: ∅ 5.25 mm and union nut with thread M10 x 1

3 - From hydraulic unit to rear right brake caliper.

- Identification: ∅ 5.25 mm and union nut with thread M10 x 1

4 - From hydraulic unit to rear left brake caliper.

- Identification: ∅ 5.25 mm and union nut with short thread M12 x 1.

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

7. ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 27/2008 37

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

7.3 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-

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

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Sealing plug -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 M10

3 - Sealing plug M12

Removing

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.

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

– 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:

– Remove connecting pipe between intake hose and turbo‐

charger.

– Remove toothed belt guard upper part.

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

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

7. ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 27/2008 39

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

– 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 sealing

plugs -1H0 698 311 A- .

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

seal.

– Pull hydraulic unit with control unit in -direction of arrow- up‐

wards out of dampers.

7.4 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.

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

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– Remove Torx bolts E5 -arrows- from hydraulic pump.

WARNING

Hydraulic pump must not be separated from hydraulic unit.

Avoid electrostatic charge!

– 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.

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

7.5 Installing new control unit

WARNING

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

7. ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 27/2008 41

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

♦ 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.

– 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.

7.6 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 131 .

– 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

Component Specified torque

Control unit to hydraulic unit ♦ Use new bolts!

Hexagon bolt of hydraulic unit to bracket 8 Nm Brake lines to ABS assembly: Thread M10 x 1 14 Nm Thread M12 x 1 14 Nm

5.5 Nm

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

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Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

8 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 27/2008

1 - ABS control unit -J104-

❑ Removing and installing

⇒ page 46 .

2 - Torx bolt

❑ 2 Nm + 0.8 Nm ❑ Use new bolts.

3 - ABS hydraulic unit -N55-

❑ Removing and installing

⇒ page 46 .

4 - Brake line

❑ 14 Nm ❑ From primary piston cir‐

cuit of brake master cyl‐ inder to hydraulic unit

❑ Identification: ∅ 6.5 mm

and union nut with thread M12 x 1

5 - Brake line

❑ 14 Nm ❑ From secondary piston

circuit of brake master cylinder to hydraulic unit

❑ Identification: ∅ 6.5 mm

and union nut with thread M12 x 1

6 - Brake line

❑ 14 Nm ❑ To front left brake cali‐

per

❑ Identification:

∅ 5.25 mm and union nut with thread M10 x 1

7 - Brake line

❑ 14 Nm ❑ To front right brake caliper ❑ Identification: ∅ 5.25 mm and union nut with thread M12 x 1

8 - Brake line

❑ 14 Nm ❑ To rear left brake caliper ❑ Identification: ∅ 5.25 mm and union nut with thread M12 x 1

9 - Brake line

❑ 14 Nm ❑ To rear right brake caliper ❑ Identification: ∅ 5.25 mm and union nut with thread M10 x 1

10 - Brake servo

❑ See ⇒ page 134 . ❑ Removing and installing ⇒ page 144 .

8. ABS Mark 60 (ABS/EDL/TCS/ESP) from week 27/2008 43

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

11 - Bracket

❑ Check for secure seating after installing.

12 - Bolt

❑ 8 Nm

13 - Rubber damper

14 - Hexagon shoulder screw

❑ 8 Nm

15 - Bracket

16 - Rubber damper

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

17 - Nut

❑ 20 Nm

18 - Heat shield

19 - Nut

❑ 8 Nm

8.1 Connecting brake lines from brake mas‐

On brake master cylinder:

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

- Identification: ∅ 6.5 mm and union nut with thread M12 x 1

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

- Identification: ∅ 6.5 mm and union nut with thread M12 x 1

1 - From hydraulic unit to front left brake caliper.

3 - From hydraulic unit to rear right brake caliper.

4 - From hydraulic unit to rear left brake caliper.

ter cylinder to hydraulic unit, left-hand drive vehicle

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

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On hydraulic unit:

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

- Identification: ∅ 6.5 mm and union nut with thread M12 x 1

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

- Identification: ∅ 6.5 mm and union nut with thread M12 x 1

1 - From hydraulic unit to front left brake caliper.

- Identification: ∅ 5.25 mm and union nut with thread M10 x 1

2 - From hydraulic unit to front right brake caliper.

- Identification: ∅ 5.25 mm and union nut with thread M12 x 1

3 - From hydraulic unit to rear right brake caliper.

- Identification: ∅ 5.25 mm and union nut with thread M10 x 1

4 - From hydraulic unit to rear left brake caliper.

- Identification: ∅ 5.25 mm and union nut with thread M12 x 1

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

8.2 Connecting brake lines from tandem brake master cylinder to hydraulic unit, right-hand drive vehicle

On tandem brake master cylinder:

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

- Identification: ∅ 6.5 mm and union nut with thread M12 x 1

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

- Identification: ∅ 6.5 mm and union nut with thread M12 x 1

1 - From hydraulic unit to front right 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 M12 x 1

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

- Identification: ∅ 6.5 mm and union nut with thread M12 x 1

1 - From hydraulic unit to front left brake caliper.

- Identification: ∅ 5.25 mm and union nut with thread M10 x 1

2 - From hydraulic unit to front right brake caliper.

- Identification: ∅ 5.25 mm and union nut with thread M12 x 1

3 - From hydraulic unit to rear right brake caliper.

- Identification: ∅ 5.25 mm and union nut with thread M10 x 1

4 - From hydraulic unit to rear left brake caliper.

- Identification: ∅ 5.25 mm and union nut with thread M12 x 1

8. ABS Mark 60 (ABS/EDL/TCS/ESP) from week 27/2008 45

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

8.3 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-

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

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Sealing plug -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 M10

3 - Sealing plug M12

Removing

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.

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

– 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:

– Remove connecting pipe between intake hose and turbo‐

charger.

– Remove toothed belt guard upper part.

Diesel engines with diesel particulate filter:

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

8. ABS Mark 60 (ABS/EDL/TCS/ESP) from week 27/2008 47

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

– Separate connector for exhaust gas temperature sender 4 -

G648- -2- and Lambda probe -G39- -3-.

– Unclip cable for exhaust gas temperature sender 4 -G648- and

Lambda probe -G39- from all brackets on plenum chamber and engine

– Pull off connector -1- on exhaust gas pressure sensor 1 -

G450- .

– Unscrew bolt -2- and remove bracket -3- with exhaust gas

pressure sensor 1 -G450- in -direction of arrow-.

– Place bracket -3- with exhaust gas pressure sensor 1 -G450-

to the front.

– Remove engine cover ⇒ Rep. Gr. 10 .

– Unscrew bolt -1- for particulate filter bracket.

– Raise vehicle.

– Loosen clamp -1- for turbocharger/particulate filter connection

The illustration shows the bolt of the clamp -1- from below. This can also be installed from above in individual cases.

and remove.

Note

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

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Golf Variant 2007 ➤ , Jetta 2005 ➤

– Detach exhaust system bracket from subframe -arrows-.

– Unscrew bolt -1- and remove drive shaft cover -2-.

– Unscrew right drive shaft from flange, place downwards and

secure.

– Loosen double clamp on exhaust pipe and slide to rear.

– Remove nuts -1 - and lower particulate filter.

– Remove nuts -2- and take out bracket for particulate filter -3-.

– Lower particulate filter until it lies on the steering gear.

Note

When lowering, be careful with the cables, the exhaust gas tem‐ perature sender 4 -G648- and the Lambda probe -G39- so as to avoid damage.

– Lower vehicle.

Continuation for all vehicles

Brake systems - Edition 12.2009

– Unscrew nut -1- and remove heat shield -2- if fitted.

8. ABS Mark 60 (ABS/EDL/TCS/ESP) from week 27/2008 49

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

– Release connector from control unit -in direction of arrow- and

pull off.

– 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 sealing

plugs -1H0 698 311 A- .

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

– Immediately seal brake lines and threaded holes with sealing

plugs -1H0 698 311 A- .

– Turn hexagon fitting bolt out of retainer -arrow-.

– Pull hydraulic unit with control unit and bracket sideways out

of rubber dampers in the console in -direction of arrow- and turn upside down.

– Unbolt retainer from hydraulic unit in engine compartment and

remove.

– Remove hydraulic unit together with control unit.

8.4 Unbolting control unit from hydraulic unit

Note

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

level surface.

– Unscrew Torx bolts out of control unit.

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

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

-arrow-.

– Carefully pull all seals from hydraulic unit contact pins.

WARNING

♦ Printed circuit board becomes visible when control unit is

removed.

♦ No moisture or particles of dirt may enter 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.

8.5 Installing new control unit

WARNING

Severe shocks (e.g. dropping, impact) may destroy control unit. 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 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.

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

8.6 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.

8. ABS Mark 60 (ABS/EDL/TCS/ESP) from week 27/2008 51

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

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 131 .

– 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

Component Specified torque

Control unit to hydraulic unit ♦ Use new bolts!

Hexagon bolt of hydraulic unit to bracket 8 Nm Hexagon fitted bolt, retainer to bracket 8 Nm Brake lines to ABS assembly: Thread M10 x 1 14 Nm Thread M12 x 1 14 Nm

2 Nm + 0.8 Nm

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

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Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

9 Removing and installing parts of ABS

system on front and rear axle

9.1 Removing and installing parts of ABS system on front axle

1 - ABS speed sensor

❑ Before inserting sensor,

clean inner surface of fit‐ ting hole and coat with hot bolt paste -G 052 112 A3-

❑ Removing and installing

⇒ page 53 .

2 - Hexagon socket head bolt

❑ 8 Nm

3 - Wheel bearing/hub unit

❑ ABS sensor ring is in‐

4 - Drive shaft

stalled in wheel bearing.

9.1.1 Removing and installing speed sensor on front axle

Removing

– Raise vehicle.

9. Removing and installing parts of ABS system on front and rear axle 53

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

– 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 sensor, clean inner surface of fitting hole and

coat speed sensor thoroughly with hot bolt 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.

9.2 Removing and installing parts of anti-lock brake system on rear axle (front-

1 - ABS speed sensor

2 - Hexagon socket head bolt

3 - Wheel bearing/hub unit

❑ Before inserting sensor,

clean inner surface of fit‐ ting hole and coat with hot bolt paste -G 052 112 A3-

❑ Removing and installing

⇒ page 55 .

❑ 8 Nm

❑ ABS sensor ring is in‐

stalled in wheel bearing.

wheel drive)

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

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Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

9.2.1 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 sensor, clean inner surface of fitting hole and

coat speed sensor thoroughly with hot bolt 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.

9.3 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 56 .

2 - Hexagon socket head bolt

❑ 8 Nm

3 - Wheel bearing/hub unit

❑ ABS sensor ring is in‐

stalled in wheel bearing.

9. Removing and installing parts of ABS system on front and rear axle 55

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

9.3.1 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.

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

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10 Removing and installing parts of ESP

system

10.1 Removing and installing ESP sensor unit -G419-

The ESP sensor unit -G419- comprises a lateral acceleration sender -G200- and a yaw rate sender -G202- . They are installed in a housing under the front passenger seat.

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 ESP sensor unit -G419-

– Remove front passenger seat ⇒ General body repairs, interi‐

or; Rep. Gr. 72 ; Front seats .

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

Gr. 68 ; Sill panel trims and raise the carpet.

– Lift carpet and lay to the side.

– Remove coupling station -1-.

– Raise floor covering.

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

10. Removing and installing parts of ESP system 57

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

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

– Remove the two securing nuts -arrows-.

– Remove ESP sensor unit -G419- .

Installing ESP sensor unit -G419-

– Carry out installation in the reverse sequence, noting the fol‐

lowing:

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.

– Carry out basic setting for lateral acceleration sender -G200-

⇒ Vehicle diagnosis, testing and information system VAS

5051.

10.2 Removing and installing steering angle sender -G85-

The steering angle sender is located between the steering wheel and steering column switch ⇒ Electrical system; Rep. Gr. 94 ; Lights, lamps, switches - outside; Steering column switch .

– After installing, perform basic settings for steering angle send‐

er -G85- .

Connecting -VAS 5051- and selecting functions ⇒ page 12 .

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 27/08.

10.3 Removing and installing brake servo vacuum sender -G483-

Removing

– Remove battery ⇒ Electrical system; Rep. Gr. 27 ; Removing

and installing batteries .

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

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– Open cover -1- and unscrew wiring -2- from carrier.

– Unscrew bolts -arrows- and 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.

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

10. Removing and installing parts of ESP system 59

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

46 – Brakes - mechanism

1 Repairing front brakes, FS III brake caliper

Note

♦

After replacing brake pads/linings, depress brake pedal firmly several times with vehicle stationary so that the brake pads/linings 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 ❑ M6 x 10 hexagon bolt re‐

vised to M6 x 12 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 not

including backplate

❑ With break pad wear in‐

dicator

❑ When wear reaches a

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

❑ Wear limit: 2 mm not in‐

cluding backplate

❑ Check thickness

⇒ Maintenance ; Book‐

let 20.1 . ❑ Always renew on both sides of an axle. ❑ Removing and installing ⇒ page 61 .

5 - Connector

❑ Brake pad wear indicator

60 Rep. Gr.46 - Brakes - mechanism

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Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

6 - Brake caliper

❑ Do not disconnect brake hose when changing pads. ❑ Removing and installing ⇒ page 64 . ❑ Repairing ⇒ page 114

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 wheel bearing.

18 - Splash plate

1.1 Removing and installing brake pads,

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

brake caliper FS III

1. Repairing front brakes, FS III brake caliper 61

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

♦ Piston resetting appliance -T10145-

Removing

Mark brake pads/linings 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.

– Remove cover caps -arrows-.

62 Rep. Gr.46 - Brakes - mechanism

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– 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.

Use only methylated spirits for cleaning the brake caliper housing.

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.

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

– 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).

1. Repairing front brakes, FS III brake caliper 63

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

– 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 torques

Component Specified torque

Guide pin to brake carrier 30 Nm

1.2 Removing and installing brake caliper,

FS III brake caliper

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

64 Rep. Gr.46 - Brakes - mechanism

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

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 caps out of bearing bushes of brake caliper.

– Loosen both guide pins and remove from brake caliper.

– Pull brake caliper off brake carrier.

– Remove brake pads from brake caliper.

Installing

• Piston is pressed 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).

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

1. Repairing front brakes, FS III brake caliper 65

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

– 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 131 .

– 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

Component Specified torque

Guide pin to brake carrier 30 Nm Brake hose to brake caliper 35 Nm

66 Rep. Gr.46 - Brakes - mechanism

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2 Repairing front brakes, FN 3 brake caliper

Note

♦

After replacing brake pads/linings, depress brake pedal firmly several times with vehicle stationary so that the brake pads/linings are properly seated in their normal operating position.

♦

Use the brake filling and bleeding equipment -VAS 5234- or the upgrade kit and extraction unit -V.A.G 1869/4- to extract brake fluid from 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 inch:

1 - Bolt

❑ 4 Nm

2 - Brake disc

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

sides of an axle.

❑ Unscrew brake caliper

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

prior to removing.

3 - Brake pads

❑ Thickness: 14 mm not

including 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.

❑ Wear limit: 2 mm not in‐

cluding backplate

❑ Check thickness

⇒ Maintenance ; Book‐ let 20.1 .

❑ Always renew on both

sides of an axle.

❑ Removing and installing

⇒ page 70 .

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 73 . ❑ Repairing ⇒ page 117

2. Repairing front brakes, FN 3 brake caliper 67

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

7 - Guide pin

❑ 30 Nm

8 - Cover cap

❑ Remove

9 - Brake hose with banjo union and banjo bolt

❑ 35 Nm

10 - Ribbed combi-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 inner surface of fitting hole and coat with hot bolt paste -G 052 112 A3-

15 - Hexagon socket head bolt

❑ 8 Nm

16 - Splash plate

17 - Hexagon bolt / Torx bolt

❑ 12 Nm ❑ M6 x 10 hexagon bolt revised to M6 x 12 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 wheel bearing.

Assembly overview, FN3, 16 inch:

68 Rep. Gr.46 - Brakes - mechanism

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1 - 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 - Bolt

❑ 4 Nm

4 - Brake pads

❑ Thickness: 14 mm not

including 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.

❑ Wear limit: 2 mm not in‐

cluding backplate

❑ Check thickness

⇒ Maintenance ; Book‐ let 20.1 .

❑ Always renew on both

sides of an axle.

❑ Removing and installing

⇒ page 70 .

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 73 . ❑ Repairing ⇒ page 117

8 - Guide pin

❑ 30 Nm

9 - Cover cap

❑ Remove

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

10 - Brake hose with banjo union and banjo bolt

❑ 35 Nm

11 - Guide pin

❑ 30 Nm

12 - Cover cap

❑ Remove

2. Repairing front brakes, FN 3 brake caliper 69

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

13 - Bolt

14 - Bracket

15 - Ribbed combi-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 wheel bearing.

20 - Splash plate

2.1 Removing and installing brake pads,

brake caliper FN 3

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

♦ Piston resetting appliance -T10145-

Removing

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

– Remove wheels.

70 Rep. Gr.46 - Brakes - mechanism

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– Lever brake pad retaining spring out from brake caliper

-arrow- with a screwdriver and remove.

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

– Remove cover caps -arrows-.

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

2. Repairing front brakes, FN 3 brake caliper 71

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

– 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.

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.

– 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 for fitting wheels .

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.

72 Rep. Gr.46 - Brakes - mechanism

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Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

Specified torques

Component Specified torque

Guide pin to brake carrier 30 Nm

2.2 Removing and installing brake caliper, FS III brake caliper

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

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

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

– Separate connector for brake pad wear indicator.

– Connect bleeder bottle hose to brake caliper bleeder valve and

screwdriver and remove.

open bleeder valve.

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

– Close bleeder valve and remove bleeder bottle.

– Disconnect brake hose.

– Pull both caps out of bearing bushes of brake caliper.

– Loosen both guide pins and remove from brake caliper.

– Pull brake caliper off brake carrier.

– Remove brake pads from brake caliper.

2. Repairing front brakes, FN 3 brake caliper 73

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

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 131 .

– Fit wheels.

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

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

Component Specified torque

Guide pin to brake carrier 30 Nm Brake hose to brake caliper 35 Nm

74 Rep. Gr.46 - Brakes - mechanism

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Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

3 Repairing rear brake C 38

Note

♦

After replacing brake pads/linings, depress brake pedal firmly several times with vehicle stationary so that the brake pads/linings 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.

♦

1 - ABS speed sensor

2 - Hexagon socket head bolt

3 - Multi-point socket head bolt

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).

❑ Before inserting sensor,

clean inner surface of fit‐ ting hole and coat with hot bolt paste -G 052 112 A3-

❑ 8 Nm

❑ 90 Nm and turn 90° fur‐

ther

❑ Always renew after re‐

moving.

4 - Wheel bearing housing

5 - Splash plate

6 - Hexagon bolt

❑ 9 Nm

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

❑ ⇒ Running gear, axles,

steering; Rep. Gr. 42 ; Assembly overview: wheel bearing housing, trailing arm (front-wheel drive)

11 - Brake pads

❑ Thickness: 11 mm not including backplate ❑ Wear limit: 2 mm not including backplate ❑ Check thickness ⇒ Maintenance ; Booklet 20.1 . ❑ Always renew on both sides of an axle. ❑ Removing and installing ⇒ page 76 .

3. Repairing rear brake C 38 75

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

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 78 . ❑ Repairing ⇒ page 121 ❑ Adjust handbrake cable first after repairing or replacement. ❑ Adjusting handbrake ⇒ page 101 .

14 - Hose retainer

15 - Brake line

❑ 14 Nm

16 - Hexagon bolt (self-locking)

❑ 35 Nm ❑ Renew.

17 - Handbrake cable

❑ Adjusting handbrake ⇒ page 101 . ❑ Allocation ⇒ Electronic parts catalogue “ETKA”

18 - Spring clip

❑ Allocation ⇒ Electronic parts catalogue “ETKA”

19 - Brake hose

3.1 Removing and installing brake pads for C 38 brake caliper

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

76 Rep. Gr.46 - Brakes - mechanism

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♦ Resetting and removal tool -T 10165-

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:

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

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.

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 piston compress‐

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

3. Repairing rear brake C 38 77

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

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

♦ If pistons are difficult to move, a 13 mm open-end spanner can

be used on intended flats -arrow A-.

– 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 .

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 torques

Component Specified torque

Hexagon bolt, brake caliper to brake carrier ♦ Use new bolts!

3.2 Removing and installing brake caliper C 38

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

35 Nm

78 Rep. Gr.46 - Brakes - mechanism

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

Removing

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

– Remove wheels.

Vehicles with spring clip on handbrake cable

– Lever spring clips off -1-.

– Press lever on brake caliper -2- in -direction of arrow- and de‐

Vehicles with locking lugs on handbrake cable

– Press locking pins -arrows- inwards.

– Press lever on brake caliper -1- in -direction of arrow- and de‐

Continuation for all vehicles

– Connect bleeder bottle hose to brake caliper bleeder valve and

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

tach handbrake cable -3-.

tach handbrake cable -2-.

open bleeder valve.

– Close bleeder valve and remove bleeder bottle.

– Unscrew brake line.

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

3. Repairing rear brake C 38 79

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

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

counterhold on guide pin.

– Pull brake caliper off brake carrier.

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 131 .

Vehicles with spring clip on handbrake cable

– Press lever on brake caliper -2- in -direction of arrow- and at‐

tach handbrake cable -3-.

– Press spring clips -1- onto handbrake cable.

Vehicles with locking lugs on handbrake cable

– Push handbrake cable into brake caliper bracket so that the

locking pins -arrows- engage.

– Press lever on brake caliper -1- in -direction of arrow- and at‐

tach handbrake cable -2-.

Continuation for all vehicles

– Adjusting handbrake ⇒ page 101 .

– 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

Component Specified torque

Hexagon bolt, brake caliper to brake carrier

35 Nm

♦ Use new bolts!

Brake line to brake caliper 14 Nm

80 Rep. Gr.46 - Brakes - mechanism

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Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

4 Repairing rear brakes CII 38/CII 41 (front-wheel drive)

Note

♦

After replacing brake pads/linings, depress brake pedal firmly several times with vehicle stationary so that the brake pads/linings are properly seated in their normal operating position.

♦

Use the brake filling and bleeding equipment -VAS 5234- or the upgrade kit and extraction unit -V.A.G 1869/4- to extract brake fluid from 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 - ABS speed sensor

❑ Before inserting sensor,

clean inner surface of fit‐ ting hole and coat with hot bolt paste -G 052 112 A3-

2 - Hexagon socket head bolt

❑ 8 Nm

3 - Multi-point socket head bolt

❑ 90 Nm and turn 90° fur‐

ther

❑ Always renew after re‐

moving.

4 - Wheel bearing housing

5 - Splash plate

6 - Hexagon bolt

❑ 9 Nm

7 - Wheel bearing/hub unit

8 - Bolt

❑ ⇒ Running gear, axles,

steering; Rep. Gr. 42 ; Assembly overview: wheel bearing housing, trailing arm (front-wheel drive)

9 - Dust cap

❑ Pressing off and driving

in ⇒ Running gear, axles, steering; Rep. Gr. 42 ; Removing and installing wheel bearing/ wheel hub unit

10 - Brake disc

❑ Brake caliper CII 38: ∅ 286 mm ❑ Brake caliper CII 41 (15”): ∅ 260 mm ❑ Brake caliper CII 41 (16”): ∅ 286 mm ❑ Thickness: 12 mm ❑ Wear limit: 10 mm ❑ When worn, renew on both sides of axle. ❑ Unscrew brake caliper prior to removing.

4. Repairing rear brakes CII 38/CII 41 (front-wheel drive) 81

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

❑ Allocation ⇒ Electronic parts catalogue “ETKA”

11 - Bolt

❑ 4 Nm

12 - Brake pads

❑ Thickness: 11 mm not including backplate ❑ Wear limit: 2 mm not including backplate ❑ Check thickness ⇒ Maintenance ; Booklet 20.1 . ❑ Always renew on both sides of an axle. ❑ Removing and installing ⇒ page 82 .

13 - 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.

❑ Allocation ⇒ Electronic parts catalogue “ETKA”

14 - Pad retainer

❑ Always renew when changing pads.

15 - Brake caliper

❑ Do not disconnect brake hose when changing pads. ❑ Removing and installing ⇒ page 85 . ❑ Repairing ⇒ page 121 ❑ Adjust handbrake cable first after repairing or renewing. ❑ Adjusting handbrake ⇒ page 101 .

16 - Hose retainer

17 - Brake line

❑ 14 Nm

18 - Hexagon bolt

❑ 35 Nm ❑ Self-locking ❑ Renew.

19 - Handbrake cable

❑ Adjusting handbrake ⇒ page 101 . ❑ Allocation ⇒ Electronic parts catalogue “ETKA”

20 - Spring clip

❑ Allocation ⇒ Electronic parts catalogue “ETKA”

21 - Brake hose

4.1 Removing and installing brake pads for C 38 brake caliper

Special tools and workshop equipment required

82 Rep. Gr.46 - Brakes - mechanism

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♦ Torque wrench -V.A.G 1331-

♦ Piston compressing tool -T10165-

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.

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

4. Repairing rear brakes CII 38/CII 41 (front-wheel drive) 83

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

– 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.

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 piston compress‐

ing tool -T10165- clockwise, do not damage protective cap when doing so.

– To aid screwing in, use plate -T10165/1- .

♦ If pistons are difficult to move, a 13 mm open-end spanner can

be used on intended flats -arrow A-.

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

84 Rep. Gr.46 - Brakes - mechanism

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– 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 for fitting wheels .

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 torques

Component Specified torque

Brake caliper to brake carrier ♦ Use new bolts!

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

35 Nm

4.2 Removing and installing brake caliper CII 38/CII 41

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

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

4. Repairing rear brakes CII 38/CII 41 (front-wheel drive) 85

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

Removing

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

– Remove wheel.

Vehicles with spring clip on handbrake cable

– Lever spring clips off -1-.

– Press lever on brake caliper -2- in -direction of arrow- and de‐

tach handbrake cable -3-.

Vehicles with locking lugs on handbrake cable

– Press locking pins -arrows- inwards.

– Press lever on brake caliper -1- in -direction of arrow- and de‐

tach handbrake cable -2-.

Continuation for all vehicles

– 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.

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 131 .

Vehicles with spring clip on handbrake cable

86 Rep. Gr.46 - Brakes - mechanism

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Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

– Press lever on brake caliper -2- in -direction of arrow- and at‐

tach handbrake cable -3-.

– Press spring clips -1- onto handbrake cable.

Vehicles with locking lugs on handbrake cable

– Push handbrake cable into brake caliper bracket so that the

locking pins -arrows- engage.

– Press lever on brake caliper -1- in -direction of arrow- and at‐

tach handbrake cable -2-.

Continuation for all vehicles

– Adjust handbrake ⇒ page 101 .

– Fit wheel.

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

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

Component Specified torque

Hexagon bolt, brake caliper to brake carrier

35 Nm

♦ Use new bolts!

Brake line to brake caliper 14 Nm

4. Repairing rear brakes CII 38/CII 41 (front-wheel drive) 87

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

5 Repairing rear brake CII 41 (four-wheel drive)

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 - Multi-point socket head bolt

❑ 90 Nm and turn 90° fur‐

ther

❑ Always renew after re‐

moving.

2 - ABS speed sensor

❑ Before inserting sensor,

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

3 - Hexagon socket head bolt

❑ 8 Nm

4 - Wheel bearing housing

5 - Splash plate

6 - Bolt

❑ M6 x 12 ❑ 12 Nm

7 - Wheel bearing/hub unit

8 - Brake disc

❑ ∅ 15 inch: 260 mm ❑ Thickness 15 inch: 12

mm,

❑ Wear limit 15 inch: 10

mm

❑ When worn, renew on

both sides of axle.

❑ Unscrew brake caliper

prior to removing.

9 - Bolt

❑ ⇒ Running gear, axles,

steering; Rep. Gr. 42 ; Assembly overview: drive shaft

10 - Cross-head screw

❑ 4 Nm

11 - Brake pads

❑ Thickness: 11 mm not including backplate ❑ Wear limit: 2 mm not including backplate ❑ Check thickness ⇒ Maintenance ; Booklet 20.1 . ❑ Always renew on both sides of an axle.

88 Rep. Gr.46 - Brakes - mechanism

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Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

❑ Removing and installing ⇒ page 89 .

12 - Brake carrier with different guide pins 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.

❑ Installation instructions ⇒ page 89

13 - Pad retainer

❑ Always renew when changing pads.

14 - Brake caliper

❑ Do not disconnect brake hose when changing pads. ❑ Removing and installing ⇒ page 92 . ❑ Repairing ⇒ page 121 ❑ Adjust handbrake cable first after repairing or replacement. ❑ Adjusting handbrake ⇒ page 101 .

15 - Hose retainer

16 - Brake line

❑ 14 Nm

17 - Hexagon bolt

❑ 35 Nm ❑ Self-locking ❑ Always renew after removing.

18 - Handbrake cable

❑ Adjusting handbrake ⇒ page 101 . ❑ Removing and installing ⇒ page 103 .

19 - Spring clip

ings

20 - Brake hose

Installation instructions for brake carrier:

1 - Shorter guide pin with steps -arrows-, leading side

2 - Longer guide pins, phasing out

3 - Balance weight, phasing out

5.1 Removing and installing brake pads/lin‐

Special tools and workshop equipment required

5. Repairing rear brake CII 41 (four-wheel drive) 89

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

♦ Torque wrench -V.A.G 1331-

♦ Resetting and removal tool -T 10165-

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.

90 Rep. Gr.46 - Brakes - mechanism

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– 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.

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 piston compress‐

ing 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, a 13 mm open-end spanner can

be used on intended flats -arrow A-.

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

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

5. Repairing rear brake CII 41 (four-wheel drive) 91

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

– 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 .

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 torques

Component Specified torque

Hexagon bolt, brake caliper to brake carrier ♦ Use new bolts!

35 Nm

5.2 Removing and installing brake caliper

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1331-

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

92 Rep. Gr.46 - Brakes - mechanism

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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.

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 131 .

– 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 .

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

Golf Variant 2007 ➤ , Jetta 2005 ➤

Brake systems - Edition 12.2009

Component Specified torque

Hexagon bolt, brake caliper to brake carrier

35 Nm

♦ Use new bolts!

Brake line to brake caliper 14 Nm

5. Repairing rear brake CII 41 (four-wheel drive) 93

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Golf Variant 2007 ➤ , Jetta 2005 ➤ Brake systems - Edition 12.2009

6 Repairing rear brakes, Bosch

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.

♦

After work for which the brake system had to be opened, bleed the brake system with brake charge and bleed system -VAS 5234- or extraction unit -V.A.G 1869/4- .

♦

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 - ABS speed sensor

❑ Before inserting sensor,

clean inner surface of hole and coat with hightemperature paste -G 052 112 A3- .

2 - Bolt

❑ 8 Nm.

3 - Bolt

❑ 90 Nm and turn 90° fur‐

ther.

❑ Always renew after re‐

moving

4 - Wheel bearing housing

5 - Splash plate

6 - Bolt

❑ 12 Nm. ❑ M6 x 12

7 - Wheel hub with wheel bear‐ ing

❑ Different for front- and

four-wheel drive.

❑ Allocation ⇒ Electronic

parts catalogue “ETKA”

❑ ⇒ Running gear, axles,

steering; Rep. Gr. 42 ; Repairing rear wheel suspension, drive shaft

8 - Bolt

❑ Different for front- and

four-wheel drive.

❑ Allocation ⇒ Electronic

parts catalogue “ETKA”

❑ ⇒ Running gear, axles, steering; Rep. Gr. 42 ; Repairing rear wheel suspension, drive shaft

9 - Dust cap

❑ Front-wheel drive only

10 - Brake disc

❑ ∅ 272 mm ❑ Thickness: 10 mm ❑ Wear limit: 8 mm

94 Rep. Gr.46 - Brakes - mechanism

Volkswagen Golf Variant 2007 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

00 – Technical data

1 Brake allocation via PR number

1.1 Front brakes, Jetta

1.2 Front brakes, Jetta, North America

1.3 Front brakes, Jetta, Japan

1.4 Front brakes, Bora, Mexico

1.5 Front brakes, Golf Variant model year 2008

1.6 Front brakes, Golf Variant from model year 2009

1.7 Front brakes, Jetta SportWagen as of model year 2008 (USA)

1.8 Rear brakes, Jetta up to week 50/2009

1.9 Rear brakes, Jetta as of week 50/2009

1.10 Rear brakes, Jetta, North America, up to week 50/2009

1.11 Rear brakes, Jetta, North America, as of week 50/2009

1.12 Rear brakes, Bora, Mexico, up to week 50/2009

1.14 Rear brakes, Jetta, Japan, up to week 50/2009

1.15 Rear brakes, Jetta, Japan, as of week 50/2009

1.16 Rear brakes, Golf Variant from model year 2008

1.18 Rear brakes, Jetta SportWagen as of model year 2009 (USA)

2 Technical data for brakes

2.1 Brake master cylinder and brake servo

2.2 Front brakes FS III

2.3 Front brakes FN 3 (15”)

2.4 Front brakes FN 3 (16”)

2.5 Rear brakes C 38

2.6 Rear brakes CII 38

2.7 Rear brake CII 41 (15")

2.8 Rear brake CII 41 (16")

2.9 Rear brakes, Bosch

3 Brake test

3.1 General

3.2 Test for vehicles with front-wheel drive

45 – Anti-lock brake system

2. Notes for repair work on anti-lock brake system 11

4.1 ABS Mark 70 (ABS/TCS)

4.2 ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 27/2008

4.3 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 27/2008

5 Fault display via warning lamps

5.1 ABS/TCS

5.2 ABS/EDL/TCS/ESP

6 ABS Mark 70 (ABS/TCS)

6.1 Connecting brake lines from tandem brake master cylinder to hydraulic unit, left-hand drive vehicle

6.2 Connecting brake lines from tandem brake master cylinder to hydraulic unit, right-hand drive vehicle

6.3 Removing control unit and hydraulic unit

6.4 Unbolting control unit from hydraulic unit

6.5 Installing new control unit

6.6 Installing control unit and hydraulic unit

7 ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 27/2008

7.2 Connecting brake lines from tandem brake master cylinder to hydraulic unit, right-hand drive vehicle

7.3 Removing control unit and hydraulic unit

7.4 Unbolting control unit from hydraulic unit

7.5 Installing new control unit

7.6 Installing control unit and hydraulic unit

8 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 27/2008

8.2 Connecting brake lines from tandem brake master cylinder to hydraulic unit, right-hand drive vehicle

8.3 Removing control unit and hydraulic unit

8.4 Unbolting control unit from hydraulic unit

8.5 Installing new control unit

8.6 Installing control unit and hydraulic unit

9.1 Removing and installing parts of ABS system on front axle

9.1.1 Removing and installing speed sensor on front axle

9. Removing and installing parts of ABS system on front and rear axle 53

9.2.1 Removing and installing speed sensor on rear axle

9.3.1 Removing and installing speed sensor on rear axle

10.1 Removing and installing ESP sensor unit -G419-

10. Removing and installing parts of ESP system 57

10.2 Removing and installing steering angle sender -G85-

10.3 Removing and installing brake servo vacuum sender -G483-

46 – Brakes - mechanism

1 Repairing front brakes, FS III brake caliper

2 Repairing front brakes, FN 3 brake caliper

2.2 Removing and installing brake caliper, FS III brake caliper

3 Repairing rear brake C 38

3.1 Removing and installing brake pads for C 38 brake caliper

3.2 Removing and installing brake caliper C 38

4 Repairing rear brakes CII 38/CII 41 (front-wheel drive)

4.1 Removing and installing brake pads for C 38 brake caliper