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.
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2010 Volkswagen AG, Wolfsburg MEX5R005520
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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‐
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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
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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