Professional Documents
Culture Documents
MK1
RUNNING GEAR
CHASSIS
RUNNING GEAR..........................................................................................................................................10
CHASSIS.........................................................................................................................................................10
TECHNICAL DATA......................................................................................................................................10
CHASSIS - SPECIFIED VALUES........................................................................................................................10
STEERING......................................................................................................................................................13
BRAKES.........................................................................................................................................................14
Brake variants and their assignment........................................................................................................14
Brake fluid................................................................................................................................................17
WHEELS, TYRES............................................................................................................................................18
FRONT SUSPENSION, DRIVE SHAFTS..................................................................................................21
REPAIRING FRONT WHEEL SUSPENSION.........................................................................................................21
l - Summary of components assembly carrier, anti-roll bar, track cotrol arm.........................................22
Removing and installing the track control arm........................................................................................25
Pressing out and in the bearing for the track control arm.......................................................................28
Removing and installing assembly carrier...............................................................................................31
Pressing out and in rubber-metal bearing................................................................................................34
II - Summary of components of the wheel bearing, suspension strut, drive shaft, brake.........................35
Repairing wheel bearing housing.............................................................................................................40
Inspecting the steering joint.....................................................................................................................43
Removing and installing the steering joint...............................................................................................44
Remove and install suspension strut and wheel bearing housing............................................................45
Repairing the suspension strut.................................................................................................................49
Inspecting the shock absorber..................................................................................................................52
Disposing of the shock absorber..............................................................................................................54
Removing and installing a drive shaft......................................................................................................57
REPAIRING DRIVE SHAFT...............................................................................................................................61
Repairing drive shaft with outer and inner CV joint VL 3700.................................................................64
Inspecting outer CV joint..........................................................................................................................73
Inspecting inner CV joint..........................................................................................................................75
Repairing drive shaft with inner tripod joint AAR 2900 and outer CV joint............................................79
Disassembling and assembling the tripod joint AAR 2900......................................................................82
Repairing drive shaft with inner tripod joint AAR 2000 and outer CV joint............................................87
Disassembling and assembling the tripod joint AAR 2000......................................................................90
REAR SUSPENSION, DRIVE SHAFT.......................................................................................................94
REPAIRING REAR AXLE - DRUM BRAKE.........................................................................................................94
Removing and installing rear suspension.................................................................................................94
Summary of components of rear axle.......................................................................................................98
Replacing the rubber-metal bearing......................................................................................................102
Replacing the rubber-metal bearing - version 1..................................................................................102
Replacing the rubber-metal bearing - version 2..................................................................................111
Removing and installing shock absorber/spring....................................................................................122
Disassembling and assembling shock absorber.....................................................................................124
REPAIRING REAR AXLE - DISC BRAKE.........................................................................................................126
Removing and installing rear suspension...............................................................................................126
2
Tyre disassembly.....................................................................................................................................244
Assembly of new tyres.............................................................................................................................245
Disposing of tyre sealant........................................................................................................................246
ABS, ADR, TCS, EDL, ESP........................................................................................................................247
ANTILOCK BRAKING SYSTEM (ABS) ITT MARK 20 IE..............................................................................247
Safety precautions, basic information on fault finding and on repairing ABS and ABS/EDL ITT Mark 20
IE............................................................................................................................................................247
Notes on repair work on ABS and ABS/EDL ITT Mark 20 IE................................................................248
Required technical information..............................................................................................................249
DISTINGUISHING FEATURES OF THE ABS ITT MARK 20 IE AND THE ABS/EDL ITT MARK 20 IE...........250
General Instructions...............................................................................................................................250
ABS ITT Mark 20 IE...............................................................................................................................251
ABS/EDL ITT Mark 20 IE......................................................................................................................252
Fitting position ABS or ABS/EDL ITT Mark 20 IE................................................................................253
SELF-DIAGNOSIS..........................................................................................................................................254
Self-diagnosis functions..........................................................................................................................254
Indication of faults by means of warning lights -K47- and -K14/33-.....................................................255
Vehicle fitted with ABS/EDL - EDL does not operate.............................................................................256
PERFORM SELF-DIAGNOSIS..........................................................................................................................257
Test requirements....................................................................................................................................257
Connecting vehicle system tester -V.A.G 1552- and selecting function..................................................258
Interrogating control unit version..........................................................................................................259
Overview of selectable functions............................................................................................................261
Interrogating fault memory....................................................................................................................262
Automatic test sequence.........................................................................................................................263
Fault table..............................................................................................................................................264
Erasing fault memory.............................................................................................................................271
Ending output.........................................................................................................................................272
Coding control unit.................................................................................................................................273
Reading measured value block...............................................................................................................275
Actuator diagnosis..................................................................................................................................278
Basic setting............................................................................................................................................283
ELECTRICAL TEST OF THE ABS AND ABS/EDL ITT MARK 20 IE.............................................................287
Test conditions........................................................................................................................................288
Multi-pin plug connection with contact assignment...............................................................................289
Overview of test steps.............................................................................................................................291
Test table.................................................................................................................................................292
ELECTRIC/ELECTRONIC COMPONENTS AND FITTING LOCATIONS ABS, ABS/EDL MARK 20.....................299
Removing and installing the hydraulic control unit and the bracket.....................................................302
Repairing the hydraulic control unit......................................................................................................309
Checking/removing and installing parts of the ABS system on the front axle........................................313
Checking/removing and installing parts of the ABS system on the rear axle (disc brake and drum brake)
- front-wheel drive..................................................................................................................................320
Removing and installing as well as adjusting brake light switch up to model year 1999......................327
Removing and installing as well as adjusting brake light switch as of model year 2000......................329
SUMMARY OF COMPONENTS OF HYDRAULIC CONTROL UNIT, BRAKE SERVO UNIT/MASTER BRAKE
CYLINDER FOR VEHICLES WITH ABS, ABS/EDL MARK 20.......................................................................330
4
SELF-DIAGNOSIS OF THE ABS/EDL FOR FOUR-WHEEL DRIVE VEHICLES WITH HALDEX COUPLING..........333
Interrogating control unit version..........................................................................................................334
Fault table for the ABS/EDL of four-wheel drive vehicles with Haldex coupling..................................335
Code ABS/EDL control unit....................................................................................................................336
Check longitudinal acceleration sender -G251-....................................................................................336
Checking the data BUS cable.................................................................................................................338
Initiating basic setting............................................................................................................................340
Switch off longitudinal acceleration sender -G251-..............................................................................340
Null balance of the longitudinal acceleration sender -G251-................................................................341
ELECTRICAL TEST OF THE ABS/EDL FOR FOUR-WHEEL DRIVE VEHICLES WITH HALDEX COUPLING........342
Test table.................................................................................................................................................343
ELECTRIC/ELECTRONIC COMPONENTS AND FITTING LOCATIONS (FOUR-WHEEL DRIVE).............................345
Removing and installing longitudinal acceleration sender -G251-.......................................................348
Checking/removing and installing parts of the ABS system on the rear axle (disc brake) - four-wheel
drive........................................................................................................................................................349
ANTILOCK BRAKING SYSTEM ABS/ EDL/ESP MARK 20...........................................................................354
Safety precautions, basic information on fault finding and on repairing...............................................354
Notes on repair work on ABS/EDL/ESP Mark 20..................................................................................354
Required technical information..............................................................................................................354
DISTINGUISHING FEATURES OF THE ABS/EDL ITT MARK 20 IE AND THE ABS/EDL/ESP ITT MARK 20 IE
....................................................................................................................................................................355
General Instructions...............................................................................................................................355
ABS/EDL/ESP ITT Mark 20 IE..............................................................................................................356
Fitting position ABS/EDL/ESP ITT Mark 20 IE.....................................................................................357
SELF-DIAGNOSIS OF THE ABS/EDL/TCS/ESP MARK 20...........................................................................358
Description of the function.....................................................................................................................358
Indication of faults by means of warning lights -K47-, -K14/33- and -K155-.......................................359
Vehicle fitted with ABS/EDL/ESP - EDL does not operate.....................................................................363
ELECTRICAL TEST OF THE ABS/EDL/ESP ITT MARK 20 IE......................................................................364
Test conditions........................................................................................................................................365
Multi-pin plug connection with contact assignment...............................................................................367
Test table.................................................................................................................................................372
Test steps 1 - 20......................................................................................................................................373
Test steps 21 - 28....................................................................................................................................384
ELECTRIC/ELECTRONIC COMPONENTS AND FITTING LOCATIONS ABS/EDL/ESP MARK 20.......................393
Removing and installing the hydraulic control unit ABS/EDL/ESP and the bracket.............................398
Repairing the hydraulic control unit ABS/EDL/ESP..............................................................................406
Checking/removing and installing parts of the ABS system on the front axle........................................410
Checking/removing and installing parts of the ABS system on the rear axle (disc brake and drum brake)
- front-wheel drive..................................................................................................................................415
Removing and installing parts of the ESP system..................................................................................415
Removing and installing as well as setting the brake light switch.........................................................422
SUMMARY OF COMPONENTS OF HYDRAULIC CONTROL UNIT, BRAKE SERVO UNIT/MASTER BRAKE
CYLINDER FOR VEHICLES WITH ABS/EDL/ESP MARK 20.........................................................................423
ANTILOCK BRAKING SYSTEM (ABS) MK60...............................................................................................427
Safety precautions, basic information on fault finding and on repairing ABS and ABS/TCS/EDL MK 60
................................................................................................................................................................427
Notes on repair work on ABS and ABS/TCS/EDL MK 60......................................................................427
5
BLEED BRAKE SYSTEM, VEHICLES WITH OR WITHOUT ABS OR ABS/EDL MARK 20 AND MARK 60........579
Bleeding brake system with brake filling and bleeding device for vehicles with Mark 20....................579
Bleeding the brake system without using the brake filling and bleeding device....................................579
Bleeding brake system with brake filling and bleeding device for vehicles with ABS Mark 60.............579
CHECKING THE MASTER BRAKE CYLINDER FOR TIGHTNESS.......................................................................579
SUMMARY OF COMPONENTS: BRAKE SERVO UNIT/MASTER BRAKE CYLINDER FOR VEHICLES WITH
ABS/EDL/ESP MARK 20...........................................................................................................................581
Removing and installing brake pressure sender -1--G201- and brake pressure sender -2--G214-.......584
Removing and installing the master brake cylinder - LHD vehicles......................................................586
Removing and installing the master brake cylinder - RHD vehicles......................................................589
Check brake servo unit...........................................................................................................................592
Removing and installing the brake servo unit - LHD vehicles...............................................................592
Removing and installing the brake servo unit - RHD vehicles...............................................................596
Removing and installing the vacuum pump for the brake servo unit.....................................................599
SUMMARY OF COMPONENTS: BRAKE SERVO UNIT/MASTER BRAKE CYLINDER FOR VEHICLES WITH
ABS/EDL/TCS/ESP MARK 60...................................................................................................................599
Removing and installing brake pressure sender -1--G201-...................................................................602
Removing and installing master brake cylinder.....................................................................................602
Check brake servo unit...........................................................................................................................602
Removing and installing brake servo unit..............................................................................................602
Removing and installing brake vacuum pump -V192-...........................................................................602
Testing brake vacuum pump -V192-.......................................................................................................603
STEERING...................................................................................................................................................604
STEERING COLUMN AND STEERING WHEEL WITH AIRBAG..........................................................................604
Check the steering column for damage..................................................................................................604
Removing and installing steering column..............................................................................................605
Removing and installing the ignition lock housing with the steering column mounted.........................618
SUMMARY OF COMPONENTS OF POWER-STEERING GEAR - LHD VEHICLES................................................621
Removing and installing hydraulic oil reservoir....................................................................................624
REMOVING AND INSTALLING THE POWER-STEERING GEAR - LHD VEHICLES.............................................626
Repairing power-steering gear (ZF)......................................................................................................634
Modified track rod ends..........................................................................................................................641
Modified track rods................................................................................................................................642
Disposing of the power-steering gear....................................................................................................643
Adjusting the power-steering gear (ZF).................................................................................................644
Check the hydraulic oil level of the power-assisted steering, top up if necessary.................................645
Draining, filling and bleeding the power-assisted steering system........................................................647
Checking the power steering system for leaks........................................................................................649
Power steering noises.............................................................................................................................651
SUMMARY OF COMPONENTS OF POWER-STEERING GEAR - RHD VEHICLES...............................................652
Removing and installing hydraulic oil reservoir....................................................................................656
Removing and installing the power-assisted steering gear - RHD vehicles...........................................658
Repairing power-steering gear (ZF) - RHD vehicles.............................................................................665
SUMMARY OF COMPONENTS: VANE PUMP FOR POWER-ASSISTED STEERING..............................................668
Summary of components for the vane pump located at the top and bottom...........................................668
PAS pressure switch................................................................................................................................671
Check the feed pressure of the vane pump..............................................................................................673
8
Running gear
Chassis
Technical data
Chassis - Specified values
Chassis
- 33' 30'
30'
- 16' 30'
30'
1 30' 20'
1 31' 20'
1 27' 20'
6 35'
6 40'
6 35'
40
39 45'
40 45'
7 15' 30' 8)
7 15' +30', -60' 9)
30'
Comment: Technical data apply for the unladen weight of the vehicle ready for driving (full fuel tank and
water reservoir for the windscreen wiper washer system, spare wheel, tool kit, jack and without driver).
1)
Not valid for Octavia 4x4
2)
Values are also valid for Octavia RS vehicles
9
3)
PR Nos. are not displayed on the vehicle data sticker. The allocation of the
adjusting values to the relevant running gear occurs via the PR No. of the front axle
damping.
Overall track -not
20' 10'
30' 10'
15' 10'
2)
4)
adjustable30' 15'
25' 15' 5)
6)
Camber -not adjustable- 1 36' 20'
- 1 36' 20' 6)
- 1 27' 20' 7)
- 1 27' 20' 7)
- 1 27' 20'
4)
Max. difference
between left and right
side
Max. misalignment of
the rear axle3)
- 1 43' 20' 4)
- 1 35' 20' 5)
30'
30'
30'
20'
20'
20'
Comment: Technical data apply for the unladen weight of the vehicle ready for driving (full fuel tank and
water reservoir for the windscreen wiper washer system, spare wheel, tool kit, jack and without driver).
1)
Values are also valid for Octavia RS vehicles
2)
The mean of the individual track values can be taken by moving the mounting brackets
3)
The mean value of the misalignment can be taken by moving the rear axle body
4)
Only Service Mobil (Octavia 1.9 ltr./66 kW SLX, Octavia 1.8 ltr./92 kW SLX)
5)
Only Service Mobil (Octavia 1.9 ltr./66 kW GLX, Octavia Combi 1.9 ltr./81 kW SLX)
6)
up to 11.96
7)
as of 12.96
Specified values rear axle - four-wheel drive
Twist-beam rear axle
PR Nos. are not displayed on the vehicle data sticker. The allocation of the
adjusting values to the relevant running gear occurs via the PR No. of the front
axle damping.
Overall track -not
15' 10'
adjustable-1)
Camber -not adjustable-30' 20'
10
30'
20'
Comment: Technical data apply for the unladen weight of the vehicle ready for driving (full fuel tank and
water reservoir for the windscreen wiper washer system, spare wheel, tool kit, jack and without driver).
1)
The mean of the individual track values of the rear axle can be taken by moving the mounting brackets
2)
The running direction of the rear axle can be corrected by moving the mounting brackets
Nominal values rear axle
Chassis denominations with PR numbers
Different chassis are offered as additional equipment. These chassis are identified by PR numbers.
The type of chassis is identified by a chassis PR number on the vehicle data sticker.
The vehicle data sticker is located at the rear left on the luggage compartment floor and in the Service
Schedule.
11
Steering
Model
Type of steering
Steering gear
Steering-wheel turns from stop to stop
Steering wheel diameter (mm)
Overall ratio of the steering
Lubricant for gear racks
12
All
Rack and pinion type steering system
Power-steering gear
3,04
370
15,60
Fluid grease for steering gear
TL 733
N 052 733 00
Part No.: AOF 063 000 04
(e.g. DEA ORNA F6 EPO)
23 to 27
0,05 to 0,1
250
1 to 3,5
Hydraulic oil
TL 52 146
N 052 146 00
Part No.: G 002 000
(e.g. PENTOSIN CHF 11S)
0,7 ... 0.9 Itr.
Brakes
Brake variants and their assignment
Engine
S = Manual gearbox
A = Automatic gearbox
Master brake cylinder -
Brake servo unit -
t
Front disc brake:
Front brake caliper
Front brake caliper, piston -
Front brake disc -
Brake disc, thickness
Brake disc, minimum thickness
Pad thickness with supporting plate
Minimum thickness without
supporting plate
t
Rear disc brake:
Rear brake caliper, piston -
Rear brake disc -
Brake disc, thickness
Brake disc, minimum thickness
Pad thickness with supporting plate
Minimum thickness without
supporting plate
t
Drum brake
Brake drum -
Brake drum - maximum diameter
Wheel-brake cylinder 1) -
Wheel-brake cylinder 2) -
Brake pad, width
Pad thickness without supporting shoe
Minimum thickness without
supporting shoe
litre/k
W
1,4/44; 1,4/55
S
1,6/55
1,6/74; 1,6/75
-
1.9/50
SDI
mm
23,81
Inch Left-hand drive with and without ABS 10''
right-hand drive with and without ABS: 7''/8''tandem
8,5
8,5
FS-III 3)
54,0
256,0
22,0
19,0
19,5
2,0
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
20,64
20,64
41,0
239,0
9,0
7,0
17,0
2,0
230,0
231,0
20,64 20,64
20,64 20,64
32,0
5,5
2,5
19,05 19,05 4)
20,64 20,64
1)
Engine
litre/k
W
1,8/132
S = Manual gearbox
A = Automatic gearbox
S
13
1,9/74
-
1,9/96
-
t
Front disc brake:
Front brake caliper
Front brake caliper, piston -
Front brake disc -
Brake disc, thickness
Brake disc, minimum thickness
Pad thickness with supporting plate
Minimum thickness without supporting
plate
t
Rear disc brake:
Rear brake caliper, piston -
Rear brake disc -
Brake disc, thickness
Brake disc, minimum thickness
Pad thickness with supporting plate
Minimum thickness without supporting
plate
t
Drum brake
Brake drum -
Brake drum - maximum diameter
Wheel-brake cylinder 1) -
Wheel-brake cylinder 2) -
Lining thickness
Pad thickness without supporting shoe
Minimum thickness without supporting
shoe
1)
2)
mm
23,81
Inch Left-hand drive with and without ABS 10''
right-hand drive with and without ABS: 7''/8''tandem
FS-III 3)
54,0
256,0
22,0
19,0
19,5
2,0
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
41,0
239,0
9,0
7,0
17,0
2,0
mm
mm
mm
mm
mm
mm
mm
Engine
S = Manual gearbox
A = Automatic gearbox
Master brake cylinder -
Brake servo unit -
t
Front disc brake:
Front brake caliper
Front brake caliper, piston -
Front brake disc -
Brake disc, thickness
litre/k
W
1.9/66 TDI
S
1,8/110
S A
mm
23,81
Inch Left-hand drive with and without ABS 10''
right-hand drive with and without ABS: 7''/8''tandem
FS-III 3)5)
54,0
280,0
22,0
mm
mm
mm
14
FN 3 4)
54,0
288,0
25,0
mm
mm
mm
mm
mm
mm
mm
mm
19,0
19,5
2,0
38,0 8)
41,0 9)
mm
mm
mm
mm
mm
mm
mm
mm
23,0
19,5
2,0
232,0 6)
239,0 7)
232,0
239,0 7)
9,0
7,0
17,0
2,0
230,0
231,0
20,64
20,64 20,64
32,0
5,5
2,5
1)
15
Brake fluid
Classification
Capacity of brake fluid
Wheels, Tyres
Wheel rims:
t
Bolt hole circle diameter: 100 mm
t
Centre hole diameter: 57 mm
t
5-hole fixing
t Tyre inflation pressures BookletOctavia I as well as sticker on the fuel-tank cap
Note
t
t
t
t
t
t
t
t
t
Only tyres of the same size and type may be fitted to the vehicle, however the same brand and tread
pattern must always be fitted to wheels on the same axle. It is exceptionally allowed to use a different
tyre temporarily in the event of breakdown. Take into account a change in driving and braking behaviour.
Use wheel bolts with spherical collar and a thread of M14 x 1.5 - tightening torque: 120 Nm.
Only use authorised rims on the relevant vehicle.
When replacing rims always use wheel bolts that belong to these rims (different length and spherical cap
shape).
Also observe the national legislation.
If winter tyres are used with a lower speed rating than the maximum permissible driving speed, it has to
be pointed out with a sticker providing an additional note which must be fixed in the field of vision of
the driver.
The information given on the sticker determines the maximum permissible driving speed for the winter
tyres fitted, which must not be exceeded during the operation of the vehicle.
The note on the sticker can be replaced with the system installed in the vehicle for life (for example the
onboard computer) Operating instructions.
On vehicles with the tyre pressure inspection system, it must be adapted again after changing one or
several wheels Operating instructions.
Caution
Tyres that are more than 6 years old must only be used in case of emergency and while driving very
carefully.
Engine
1.4 ltr./44kW
1.4 ltr./55kW
1.6 ltr./55 kW
1.9 ltr./50 kW
Wheel size 1)
6.5J x 16 H2
16
42
1.6ltr./74 kW
1.6 ltr./75 kW
2.0 ltr./85 kW
1,8 Itr./92 kW
1.8 ltr./110 kW
1.8 ltr./132 kW
1)
2)
205/55 R16 91 W
175/80 R14 88 H
195/65 R15 91 H, V
205/60 R15 91 H
205/55 R16 91 H
205/55 R16 91 W
195/65 R15 91 H, V
205/60 R15 91 H
205/55 R16 91 H
205/55 R16 91 W
195/65 R15 91 H, V
205/60 R15 91 H, V
205/55 R16 91 H, V, W
205/55 R16 91 W
195/65 R15 91 V
205/55 R16 91 V, W
205/60 R15 91 V
205/55 R16 91 W
205/55 R16 91 W
205/55 R16 91 W
205/50R17 89W2)
195/65 R15 91 T, H, V
205/60 R15 91 H
205/55 R16 91 H
205/55 R16 91 W
195/65 R15 91 V
205/60 R15 91 V
205/55 R16 91 V
205/55 R16 91 W
195/65 R15 91 H, V
205/60 R15 91 H
205/55 R16 91 H, V, W
205/55 R16 91 W
195/65 R15 91 V
205/60 R15 91 V
205/55 R16 91 V, W
205/55 R16 91 W
5,5J x 16 H2
6J x 15 H2
6.5J x 15 H2
6.5J x 16 H2
5,5J x 16 H2
6J x 15 H2
6.5J x 15 H2
6.5J x 16 H2
5,5J x 16 H2
6J x15 H2
6.5J x 15H2
6.5J x 16H2
5,5J x 16H2
6J x 15 H2
6.5J x 16H2
6.5J x 15H2
5,5J x 16H2
6.5J x 16H2
5,5J x 16H2
7J x 17 H2
6J x15 H2
6.5J x 15H2
6.5J x 16H2
5,5J x 16H2
6J x 15 H2
6.5J x 15H2
6.5J x 16H2
5,5J x 16H2
6J x 15 H2
6.5J x 15H2
6.5J x 16H2
5,5J x 16H2
6J x 15 H2
6.5J x 15H2
6.5J x 16H2
5,5J x 16H2
6J x 14 H2
6J x 15 H2
6J x 15 H2
6Jx15 H2
6Jx15 H2
6.5Jx16H2
6Jx15 H2
6Jx15 H2
6Jx15 H2
6Jx15 H2
-
36
38
38
43
42
36
38
43
42
36
38
43
42
36
38
42
43
36
42
36
38
38
43
42
36
38
43
42
36
38
43
42
36
38
43
42
36
88 = 560 kg 91 = 615 kg
89 = 580 kg
T =190km/h H = 210km/h
V = 240 km/h W = 270 km/h
Speed symbols:
17
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
-
Tyre legend
Marking e.g. 175/80 R14 88 T
175/80
R
14
88
T
Production date
DOT...394
DOT...0300
Meaning
Tyre width (mm) section ratio between height - width (%)
Tyre type (radial)
Rim diameter (inch)
Load rating-index
Speed symbol
Manufactured during week 39 of 1994
( = denomination of the decade 1990...1999)
Manufactured during week 3 of 2000
+ 03 = 3rd calendar week, 00 = year 2000)
18
I - Removing and installing assembly carrier, anti-roll bar, track control arm Chapter
II - Removing and installing wheel bearing, suspension strut, drive shaft, brake Chapter
Note
When moving vehicles with drive shaft removed, it is advisable to install an external joint instead of the
drive shaft and tighten with a torque of 50 Nm otherwise the wheel bearing may get damaged.
Welding and straightening work is not allowed on the bearing and wheel control components of the
t
wheel suspension.
t
Self-locking nuts must always be replaced.
t Always replace corroded self-locking nuts and screws.
t
19
1t
t
23t
t
4t
5t
t
t
t
6t
7t
89-
t
replace after each removal
10 40 Nm + 90
t
replace after each removal
11 20 Nm + 90
t
replace after each removal
12 Assembly carrier
t
removing and installing Chapter
t The repair of the thread for the screwed connection of the front track control arm is not permissible!
13 Self-locking nut
t
replace after each removal
t
M10 - 15 Nm + 90
t
M12 - 90 Nm
14 Anti-roll bar
t
to remove and install lower assembly carrier
15 Rubber bearing
16 25 Nm
17 Clamp
18 Coupling rod
t mount the spherical head with the long joint stub -A- (top) to the spring cap
t mount the spherical head with the short joint stub -B- (bottom) to the anti-roll bar
t Assignment Electronic Catalogue of Original Parts
19 Nut, 90 Nm
t
replace after each removal
20 Rubber-metal bearing
t
pressing in and pressing out Chapter
21 Self-locking nut
t
replace after each removal
22 100 Nm + 90
t
replace after each removal
23 Rear bearing for track control arm
t
Fitting position Anchor
t
pressing in and pressing out Anchor
24 100 Nm + 90
t
replace after each removal
25 70 Nm + 90
t
replace after each removal
26 Lock washer
t
replace after each removal
27 20 Nm + 90
t
replace after each removal
28 Steering joint
t
check Chapter
t Inspect rubber bellows for damage, if necessary replace
t removing and installing only in combination with the wheel bearing housing Chapter
mark fitting position before removal, set in the middle of the oblong hole when replacing the track control
t
arm and check track
29 20 Nm + 90
t
replace after each removal
21
22
carrier.
Note
mechanic required).
Tighten new twelve-point nut to 225 Nm and
Tightening torques:
Assembly carrier to body
t
Use new screws!
Steering joint to track control arm
t Use new screws and new lock washer!
Pendulum support to gearbox
t
Use new screws!
Coupling rod to track control arm
t
Use new screws!
100 Nm + 90
20 Nm + 90
40 Nm + 90
15 Nm + 90
Pressing out and in the bearing for the track control arm
t
t
t
t
t
t
t
t
t
Pipe section -MP 3-429Pressure washer -MP 3-456Assembly device -MP 5-402Assembly device -MP 6-401Pressure spindle -MP 6-405Base -MP 6-407Pressure pipe -MP 6-408Workshop press, e.g. -V.A.G 1290 Aacid-free lubricant, e.g. -G 294 421-
25
tool kit).
Mark installation position of bolts -1-, otherwise the steering geometry must be checked.
steering joint.
Swivel out the wheel-bearing housing with the
27
28
II - Summary of components of the wheel bearing, suspension strut, drive shaft, brake
Note
When moving vehicles with drive shaft removed, it is advisable to install an external joint instead of the
drive shaft and tighten with a torque of 50 Nm otherwise the wheel bearing may get damaged.
Welding and straightening work is not allowed on the bearing and wheel control components of the front
t
wheel suspension.
t
Always replace self-locking nuts.
t Always replace corroded self-locking nuts and screws.
t
29
1Self-locking nut, 60 Nm
t
replace after each removal
2Stop
3Suspension strut
t
removing and installing Chapter
t
repairing Chapter
t Assignment Electronic Catalogue of Original Parts
4Drive shaft with inner CV joint
t
removing and installing Chapter
t
repairing Chapter
5Shim
6Fillister head screw with internal serrations
t
replace after each removal
t initially tighten to 10 Nm and subsequently tighten crosswise to final torque:
M8 = 20 Nm + 180
M10 = 50 Nm + 45
t Assignment Electronic Catalogue of Original Parts
7Drive shaft with inner tripod joint
t
removing and installing Chapter
t
repairing Chapter
30
24 Cap (FN-3)
25 Screw with securing collar (FN-3), 124 Nm
t
Clean ribbing on the underside
26 Wheel-bearing housing
Including for vehicles with engine as of 96 kW.
t
removing and installing Chapter
t
repairing Chapter
before pressing in the wheel bearing, coat the entire wheel bearing seat in the wheel bearing housing
t
evenly with -G 052 723 A227 Cover plate
28 Self-locking nut, 50 Nm
t
replace after each removal
29 Steering joint
t
check Chapter
t Inspect rubber bellows for damage, if necessary replace
t
removing and installing Chapter
30 Wheel-bearing housing
Including for vehicles with engine up to 92 kW.
t
removing and installing Chapter
t
repairing Chapter
before pressing in the wheel bearing, coat the entire wheel bearing seat in the wheel bearing housing
t
evenly with -G 052 723 A231 Self-locking nut, 20 Nm + 90
t
replace after each removal
32 Screw
t
replace after each removal
33 8 Nm
34 ABS wheel speed sensor
t
only on vehicles with ABS
t insert with solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
35 Self-locking nut
t
up to 05.98: 50 Nm + 90
t
as of 06.98: 60 Nm + 90
t
replace after each removal
36 Track rod with track rod end
t
removing and installing Chapter
37 10 Nm
38 Wheel bearing
t
press out Chapter
t
replace, is damaged when pressing out
t
installing Chapter
The spare part is only delivered as a set wheel bearing with mounting parts (Pos. 11, 39, 38, 28, 31 and
t
35)
39 Circlip
t
pay attention to correct position Chapter
t
replace after each removal
40 Wheel hub without pulse rotor
t
only on vehicles without ABS
t Assignment Electronic Catalogue of Original Parts
41 Wheel hub with pulse rotor for wheel speed sensor
32
t
t
t
t
t
t
t
33
Replace.
When inserting, pay attention to the correct
t
position of the circlip.
34
-MP 6-416-.
Position thrust plate -MP 3-467- onto wheel
hub and pull off the inner ring of the bearing by
turning the threaded spindle.
housing.
Remove and install suspension strut and wheel bearing housing Chapter.
Tightening torques:
Steering joint to wheel-bearing housing
20 Nm + 90
Note
Mark installation position of bolts -1-, otherwise the steering geometry must be checked.
speed sensor.
Remove the ABS wheel speed sensor cable
38
suspension strut.
bearing housing.
suspension strut.
Moisten the serration of the wheel hub with oil.
Insert outer joint as far as possible into the
bearing housing.
39
Note
Tighten the FN-3 brakes at the wheel bearing
housing to 124 Nm.
Insert the cable of the ABS wheel speed sensor
mechanic required).
Tighten new twelve-point nut to 225 Nm and
Tightening torques:
Suspension strut to suspension strut dome
Coupling rod to suspension strut
t
Use new nuts!
Steering joint to track control arm
60 Nm
90 Nm
20 Nm + 90
40
t
Use new nuts!
Brake caliper housing to wheel bearing housing
t Use new screws and new lock washer!
30 Nm
t
check colour coding
t The surface of the spring coil must not be damaged
t
replace on both sides of the axle
t
per axle only use coil springs of the same make
5Spring cap
6Bush
Only present on vehicles with rough road suspension (PR No. 1GB). This PR No. can be found on the
t
vehicle data sticker in the luggage compartment or in the Service Schedule Chapter
7Axial grooved ball bearing
8Suspension strut bearing
9Collar nut, 60 Nm
t
replace after each removal
t
loosen and tighten
10 Spring cap
11 Collar nut, self-locking, 60 Nm
t
replace after each removal Fig.
42
43
45
46
is initially damaged through the vehicle's own weight, thus shortening the life of the wheel bearing.
When moving vehicles with drive shaft removed, it is advisable to install an external joint instead of the
t
drive shaft and tighten with a torque of 50 Nm otherwise the wheel bearing may get damaged.
Assignment of the drive shaft and marking electronic catalogue of original parts.
Remove wheel trim cap, for light-alloy wheels remove the cap (pull-off hook in tool kit).
48
carrier.
- Moisten the contact surface of the twelve-point
nut as well as the serration and the thread of the
outer joint with oil and screw on new twelvepoint nut as far as possible.
Insert the outer joint into the wheel hub until
mechanic required).
Tighten new twelve-point nut to 225 Nm and
Tightening torques:
Steering joint to track control arm
t Use new screws and new lock washer!
Tighten drive shaft to flange shaft diagonally across in 2 steps (I and II)
Screw M8 x 18
Screw M8 x 48
t
Use new screws!
Tighten drive shaft to flange shaft diagonally across in 2 steps (I and II)
20 Nm + 90
I.
2nd
10 Nm 20 Nm + 90
10 Nm 20Nm + 180
I.
2nd
10 Nm 50 Nm + 45
Screw M10
t
Use new screws!
Pendulum support to assembly carrier
t
Use new screws!
20 Nm + 90
t
t
t
must be replaced completely
t
removing Fig.
t install: drive onto the shaft with a plastic hammer until the compressed circlip expands
t
grease Anchor
t
check Chapter
19 22 Nm
20 M8 = 20 Nm, M10 = 33 Nm
21 Protective housing
1Outer CV joint
t
must be replaced completely
t
removing Fig.
t install: drive onto the shaft with a plastic hammer until the compressed circlip expands
t
grease Anchor
t
check Chapter
2Circlip
t
replace
53
t
insert into the groove at the shaft
3Thrust ring
t
Fitting position Fig.
4Disc spring
t
Fitting position Fig.
5Open warm-type clamp
t
replace
t tension with tensioning pliers, e.g. -V.A.G 1682-, Fig.
6Joint boot for outer CV joint
t
Material: Hytrel (Polyelastomere)
t
inspect for tears and chafing points
t
Fitting position for the left shaft Fig.
t
Fitting position for the right shaft Fig.
t Assignment Electronic Catalogue of Original Parts
7Open warm-type clamp
t
replace
t
tensioning Fig.
8Drive shaft
t Assignment Electronic Catalogue of Original Parts
9Joint boot for inner CV joint
t
Material: Arnitel (Polyelastomere)
t
inspect for tears and chafing points
t
Fitting position for the left shaft Fig.
t
Fitting position for the right shaft Fig.
t Assignment Electronic Catalogue of Original Parts
10 Open warm-type clamp
t
replace
11 Cover
t
remove from CV joint with drift
t before installation coat the sealing surface of the cap with sealant -D 454 300 A2t The sealing surface must be free of oil and grease!
12 Inner CV joint
t
must be replaced completely
t
pressing out Fig.
t
pressing on Fig.
t
grease Anchor
t
check Chapter
t Assignment Electronic Catalogue of Original Parts
13 Circlip
t
replace
t
remove with circlip pliers, e.g. -VW 161A-,
14 Fillister head screw with internal serrations
t
replace after each removal
t initially tighten to 10 Nm, subsequently tighten crosswise to final torque:
M8 x 48 = 20 Nm + 180
M10 x 52 = 50 Nm + 45
t Assignment Electronic Catalogue of Original Parts
15 Shim
t Assignment Electronic Catalogue of Original Parts
16 Gasket
54
t The adherend on the inner CV joint must be free of grease and oil!
t
replace
t Remove the protective foil from the gasket and stick it into the inner joint
t Assignment Electronic Catalogue of Original Parts
17 Cover
t
remove from CV joint with drift
t before installation coat the sealing surface of the cap with sealant -D 454 300 A2t The sealing surface must be free of oil and grease!
Grease quality and grease quantity
Note
The outer joints of the drive shaft are filled with:
Grease for operating at normal temperatures part no.: -G 052 738 A2
Grease from the relevant repair kit
High temperature grease, part no.: -G 052 133 A2-, or part no.: -G 052 133 A3The inner joints of the drive shaft must only be filled with high temperature grease from the relevant
t repair kit or with grease part no.: -G 052 133 A2-, or part no.: -G 052 133 A3- electronic catalogue of
original parts
Grease quantity Anchor
a plastic hammer.
55
56
t
t
t
tensioning pliers is
smooth. If necessary
grease with grease, e.g.
molykote MoS2.
If it is not smooth, e.g.
if the thread is dirty, the
necessary clamping
t force of the open
warm-type clamp is not
reached at the given
torque.
Position the tensioning
pliers, e.g. -V.A.G
1682-, as shown in the
fig. Make sure the
58
59
Disassemble the joint to replace badly soiled grease or if the contact surfaces of the balls must be inspected
60
joint part.
Grease quality and grease quantity Anchor.
Insert the cage with the hub in the joint part.
61
Note
The cage must be inserted in the correct position.
Press in opposite balls one after the other,
during this process observe the prior position of
Anchor.
Installing the joint boot Fig..
Disassemble the joint to replace badly soiled grease or if the contact surfaces of the balls must be inspected
for wear and damage.
Removing
Note
The ball hub and joint part are paired and must be marked before removal. Do not interchange the bearing
track assignment.
the cage.
62
63
64
exerting considerable
pressure on the cage
-arrow-.
Inspect the operation of
the inner CV joint
The CV joint is
correctly assembled if
the ball hub in the joint
l part can be rolled by
hand up and down the
entire linear
compensation.
Push the clamp and the
joint boot onto the
drive shaft.
Install drive shaft.
Press the specified
grease quantity for the
inner joint into the joint
from both sides.
Spread the prescribed
Fig..
Repairing drive shaft with inner tripod joint AAR 2900 and outer CV joint
q
insert into the groove at the shaft
10 O-ring seal
q
no longer necessary for the assembly of the repaired drive shaft
11 Oblong gasket ring
q
The gasket ring belongs to the repair set
q The gasket ring is not fitted in the series, it is only necessary for the spare parts sector
q
Assignment Electronic Catalogue of Original Parts
12 Cover
q
is damaged when removing.
is no longer necessary for the assembly of the repaired drive shaft and is therefore only available as a
q
spare part
13 Open warm-type clamp
q
for tripod joint
q
always replace
14 Joint boot for tripod joint
q
inspect for tears and chafing points
15 Open warm-type clamp
q
for tripod joint
q
always replace
q
tensioning Anchor
16 Disc spring
q
Fitting position Fig.
17 Thrust ring
q
Fitting position Fig.
18 Circlip
q
replace
q
insert into the groove at the shaft
19 Outer CV joint
q
must be replaced completely
q
removing Fig.
q install: drive onto the shaft with a plastic hammer until the compressed circlip expands
q
grease Anchor
q
check Chapter
67
help of lines.
-1- Joint part
-2- Tripod spider
-3- Drive shaft
Note
If the parts -1- ... -3- are not marked and if they
are not fitted in their original position again
t
when assembling, at a later stage this could
cause noises during driving.
t Use a waterproof marker for marking.
Hold the joint part and remove drive shaft from
the vice.
Ensure that the rollers do not topple off the tripod
spider and fall onto the floor!
Hold the drive shaft with the joint part
vertically and with the other hand gradually
push back the joint part.
68
clean surface.
Remove circlip.
-1- Circlip pliers (commercially available)
Insert the drive shaft in the press.
69
position.
Fit the rollers corresponding to the markings
down.
Clamp joint part into the vice.
70
71
Cover the tripod joint with a cardboard disc -Aand adhesive tape -B-.
Note
Repairing drive shaft with inner tripod joint AAR 2000 and outer CV joint
74
help of lines.
-1- Joint part
-2- Tripod spider
-3- Drive shaft
Note
If the parts -1- ... -3- are not marked and if they
are not fitted in their original position again
t
when assembling, at a later stage this could
cause noises during driving.
t Use a waterproof marker for marking.
Hold the joint part and remove drive shaft from
the vice.
75
Remove circlip.
-1- Circlip pliers (commercially available)
Insert the drive shaft in the press.
76
position.
Slide the joint part over the rollers and hold
down.
Remove the drive shaft from the special tool
77
Outer joint
mm
Total quantity of
grease (g)
Spread evenly in the
joint
81
90
90
110
90
90
110
110
98
130
Inner joint mm
94 (synchronous
running) 1)
100 (synchronous
running) 1)
108 (tripod) 1)
124 (tripod) 1)
100 (synchronous
running) 2)
Total quantity of
grease (g)
of which in
Joint
(g)
Joint boot
(g)
90
45
45
120
60
60
110
140
110
140
_
_
190
190
1)
Valid for all vehicles, except 1.9 ltr./74 kW PD and 1.9 ltr./96 kW PD engines.
Valid for vehicles with 1.9 ltr./74 kW PD and 1.9 ltr./96 kW PD engines.
Grease quality - outer CV joint
The outer CV joints can be filled with the following grease qualities:
t Grease for operating at normal temperatures, part no.: -G 052 738 A2t
Grease from the relevant repair kit
t High temperature grease, part no.: -G 052 133 A2-, or part no.: -G 052 133 A3Grease quality - inner CV joint
The inner CV joints can be filled with the following grease qualities:
t
Grease from the relevant repair kit
t High temperature grease, part no.: -G 052 133 A2-, or part no.: -G 052 133 A3Note
2)
Remove wheels.
79
fixture.
sensors.
Unclip the wheel speed sensor cable from the
bracket.
Only on vehicles fitted with brake-power
regulator (vehicles without ABS):
80
30 Nm + 90
45 Nm + 90
14 Nm
81
Note
t Welding and straightening on axle body and axle studs not allowed.
t Always replace the self-locking nuts and screws.
t Pipe screws of brake hoses are tightened to a tightening torque of 14 Nm.
this component is maintenance-free and requires no clearance adjustment; adjustment as well as repair
work are not possible
t
removing and installing Chapter
7Wheel hub with wheel bearing without pulse rotor
t
only on vehicles without ABS
t The wheel bearing and the wheel hub are fitted together in one housing
this component is maintenance-free and requires no clearance adjustment; adjustment as well as repair
t
work are not possible
t
removing and installing Chapter
t
must be replaced completely
850 Nm + 60
t
replace after each removal
9Brake carrier with brake shoe
10 Holder for hand-brake cable
t
replace
11 Hand-brake cable
12 Self-locking nut
t
replace after each removal
13 Self-locking screw, 30 Nm + 90
t
replace after each removal
if the thread of the weld nut is damaged, it can be repaired using Heli-Coli threaded insert; while paying
t
attention to the fitting instructions of the manufacturer
t the rework of the thread for the weld nut is permissible on maximum 2 screw points per vehicle side
14 45 Nm + 90
t
replace after each removal
t
insert from the outside of the vehicle
t when tightening the screw, the axle body must be in the horizontal position (unladen condition)
15 Mount for rear axle
t check the overall track of the rear axle after installation and adjust if necessary
t avoid slackening in order to remove the rear axle
16 Holder for hand-brake cable
17 Rubber-metal bearing
t
removing and installing Chapter
18 Socket nut
19 Brake-power regulator
t
only on vehicles without ABS
t
testing and adjusting Chapter
20 20 Nm
21 16 Nm
22 20 Nm + 45
t
replace after each removal
23 Balancing weight
24 Axle body
t The locating face and the threaded holes for axle studs must be free from enamel and dirt
25 ABS wheel speed sensor
t
only on vehicles with ABS
26 8 Nm
27 bottom base
28 Coil spring
t
removing and installing Chapter
t
83
84
85
86
adapter.
Vehicles with fixing screws mounted on the
outside
87
88
89
90
bearing.
Grease the kidney-shaped cavities of the
rubber-metal bearing with assembly paste
-G052 150 A2-.
Vehicles with fixing screws mounted on the
outside
Carefully raise the rear axle so that the rubber metal bearing engages in the bearing brackets
for the axle.
regulator Chapter.
Continued for all vehicles
92
45 Nm + 90
30 Nm + 90
16 Nm
16 Nm
93
94
adapter.
Vehicles with fixing screws mounted on the
outside
95
96
97
98
99
bearing.
100
101
regulator Chapter.
Continued for all vehicles
102
45 Nm + 90
30 Nm + 90
16 Nm
16 Nm
103
supports.
Raise the relevant side of the axle body with
spring.
Install
Installation is carried out in the reverse order.
Note
104
1Shock absorber
t
can be replaced individually
t
removing and installing Chapter
t Assignment Electronic Catalogue of Original Parts
t
disposing of Chapter
t
Inspecting the shock absorber Chapter
Note
The shock absorbers must not be disassembled and repaired.
2Protective cap
3Protective tube
4Stop buffer
5Top shock absorber bushing
6Self-locking screw, 25 Nm
t
replace after each removal
t counterhold the piston rod of the shock absorber in order to slacken and tighten the nut
7Protective cap
105
106
fixture.
sensors.
Unclip the speed sensor cable from the
brackets.
Support the rear axle with gearbox jack with
adapter, e.g. -V.A.G 1383 A- with -V.A.G
1359/2-.
Release the hexagon screws -1- of the rubbermetal bearing and remove the rear axle.
Install
Before inserting the rear axle, grease the
kidney-shaped cavities of the rubber-metal
bearings with assembly paste -G 052 150 A2-.
Installation is carried out in the reverse order.
Note
Note
After slackening or changing the mounting
bracket, check the overall track of the rear axle,
adjust if necessary.
Tightening torques:
Shock absorber to body
t
Use new screws!
Rear suspension to bearing bracket
t
Use new screws and nuts!
Pipe screws to brake lines
Fixing screws for brake caliper
30 Nm + 90
45 Nm + 90
14 Nm
30 Nm + 30
Note
t Welding and straightening on axle body and axle studs not allowed.
t Always replace the self-locking nuts and screws.
t Pipe screws of brake hoses are tightened to a tightening torque of 14 Nm.
108
1234t
t
t
While the vehicle is standing on its wheels, load the luggage compartment with approx. 100 kg and
tighten the screw
26 Self-locking screw, 30 Nm + 90
t
replace after each removal
if the thread of the weld nut is damaged, it can be repaired using Heli-Coli threaded insert; while paying
t
attention to the fitting instructions of the manufacturer
t the rework of the thread for the weld nut is permissible on maximum 2 screw points per axle
27 Shock absorber
t
can be replaced individually
t
removing and installing Chapter
t Assignment Electronic Catalogue of Original Parts
t
disposing of Chapter
t
Inspecting the shock absorber Chapter
t per rear axle only use shock absorbers of the same make
Note
t
111
112
113
adapter.
Vehicles with fixing screws mounted on the
outside
114
115
116
117
bearing.
Grease the kidney-shaped cavities of the
rubber-metal bearing with assembly paste
-G052 150 A2-.
Vehicles with fixing screws mounted on the
outside
Carefully raise the rear axle so that the rubber metal bearing engages in the bearing brackets
for the axle.
regulator Chapter.
Continued for all vehicles
119
45 Nm + 90
30 Nm + 90
16 Nm
16 Nm
120
121
adapter.
Vehicles with fixing screws mounted on the
outside
122
123
124
125
126
bearing.
127
128
regulator Chapter.
Continued for all vehicles
129
45 Nm + 90
30 Nm + 90
16 Nm
16 Nm
130
spring.
Install
Installation is carried out in the reverse order.
Note
131
1Shock absorber
t
can be replaced individually
t
removing and installing Chapter
t Assignment Electronic Catalogue of Original Parts
t
disposing of Chapter
t
Inspecting the shock absorber Chapter
Note
The shock absorbers must not be disassembled and repaired.
2Protective cap
3Protective tube
4Stop buffer
5Top shock absorber bushing
6Self-locking nut, 25 Nm
t
replace after each removal
t counterhold piston rod of shock absorber at the tip in order to slacken and tighten the hexagon nut
7Protective cap
132
14 Nm
2Brake drum
t reset brake before removing the brake drum Fig.
3Cap
t
replace after each removal
t
press off Fig. and Fig.
t
inserting Fig.
4Self-locking twelve-point nut 70 Nm +40
t
replace after each removal
5Wheel hub with wheel bearing and pulse rotor
t
only on vehicles with ABS
t The wheel bearing and the wheel hub are fitted together in one housing
this component is maintenance-free and requires no clearance adjustment; adjustment as well as repair
t
work are not possible
t
replace completely after each removal
t Remove wheel hub with wheel bearing from axle stud Fig.
t Pull wheel hub with wheel bearing onto axle stud Fig. and Fig.
133
Note
If the inner ring of the bearing remains on the axle stud after pulling off the wheel hub with wheel
t bearing, the old inner ring of the bearing must be pulled off before pressing on the new wheel hub with
wheel bearing Fig..
The inner ring of the bearing is a component part of the new wheel hub with wheel bearing and is
t
therefore not pressed on separately.
6Wheel hub with wheel bearing without pulse rotor
t
only on vehicles without ABS
t The wheel bearing and the wheel hub are fitted together in one housing
this component is maintenance-free and requires no clearance adjustment; adjustment as well as repair
t
work are not possible
t
replace completely after each removal
t Remove wheel hub with wheel bearing from axle stud Fig.
Note
Item
t Pull wheel hub with wheel bearing onto axle stud Fig. and Fig.
7Axle stud
t
Straightening work is not allowed!
8Axle body
t
Straightening work is not allowed!
t
Re-cutting the thread is not allowed
Resetting brake
To do so, use a screwdriver to push the wedge
134
the claw.
135
136
Drive in cap
Note
t Replace cap after each removal.
Damaged caps allow moisture to penetrate.
t
Therefore absolutely use the shown tool.
Tightening torques:
Wheel hub with wheel bearing on axle stud
70 Nm + 40
137
8Axle body
t
removing and installing Chapter
9Brake caliper
t
dismantling Fig.
10 Axle stud
t
Straightening work is not allowed!
t
Re-cutting the thread is not allowed.
the claw.
139
140
and tighten.
Drive in cap
Note
t Replace cap after each removal.
Damaged caps allow moisture to penetrate.
t
Therefore absolutely use the shown tool.
Install brake caliper and tighten Allen screws.
Tightening torques:
Wheel hub with wheel bearing on axle stud
Securing screw for brake disc
Screws for brake caliper
70 Nm + 40
4 Nm
65 Nm
141
142
Note
t
t
1Assembly carrier
t
Summary of components Chapter
2Final drive
t removing and installing manual gearbox; Rep. gr.39.
t
repairing Manual Gearbox; Rep. gr.39
3Cross member
4Clamp
5Anti-roll bar
t If necessary eliminate paint damage and carry out protection work against corrosion
6Pressurized shock absorber
t
Summary of components Chapter
t
removing and installing Chapter
7The wheel bearing
143
t
pressing in and pressing out Chapter
8Trailing arm
t
Summary of components Chapter
9Suspension arm
t
Summary of components Chapter
10 Spacer
t
only on vehicles with rough road suspension
t on vehicles without spacer, none must be subsequently fitted
t
Summary of components Chapter
11 Stop buffer
t
Summary of components Chapter
12 Coil spring
t
Summary of components Chapter
13 Propshaft
t removing and installing manual gearbox; Rep. gr.39.
t
repairing Manual Gearbox; Rep. gr.39
14 60 Nm
15 Support for final drive
144
Coil spring and shock absorber on vehicles with four-wheel drive - Summary of components
160 Nm
t
replace after each removal
2Shock absorber bushing
3Pressurized shock absorber
t
removing and installing Chapter
t
check Chapter
t Assignment Electronic Catalogue of Original Parts
t
disposing of Chapter
t
can be replaced individually
t per rear axle only use shock absorbers of the same make
4Anti-roll bar
5Self-locking nut 25 Nm
t
replace after each removal
6110 Nm
7Coupling rod
8Trailing arm
t The thread -arrow A- for the support of the stop buffer Item is no longer applicable as of 08.99
if it is intended to install the stop buffer Item in the trailing arm before the manufacturing date 08.99,
t
the thread -arrow A- must be bored out to 10.5 mm
9Spacer
t
only on vehicles with rough road suspension
t on vehicles without spacer, none must be subsequently fitted
10 Stop buffer with threaded pin, 10 Nm
t
is no longer inserted as of 08.99
t the stop buffer is delivered as a spare part Item
145
t Ensure that the spring holders are positioned as close as possible to the spring coils.
t During the tensioning operation, ensure that the spring holder is correctly located at the spring coils.
t
Do not use impact screwdriver!
Remove left coil spring
146
147
Note
Make sure to end the tensioning operation once
the spring coils touch each other
tensioning device.
1 - Spring holder, e.g. -V.A.G 1752/1-.
2 - Spring holder, e.g. -V.A.G 1752/1 5 L. O-.
3 - Spring holder, e.g. -V.A.G 1752/1 5 L. U-.
Install left coil spring
149
tensioning device.
Removing and installing right coil spring
The removal and installation procedure of the
right coil spring is carried out in the same way as
for the left coil spring Chapter.
Instead of the special tools
Spring holder, e.g. -V.A.G 1752/1 5 L. U-.
t
(bottom left)
Spring holder, e.g. -V.A.G 1752/1 5 L. O-. (top
t
left)
the
Spring holder, e.g. -V.A.G 1752/1 5 R. U-.
t
(bottom right)
Spring holder, e.g. -V.A.G 1752/1 5 R. O-.
t
(bottom right) must be used.
Fitting position of the right coil spring
The fitting position of the right coil spring is
identical to the fitting position of the left coil
spring Anchor.
Raise vehicle.
Remove wheel.
150
Tightening torques:
Shock absorber to body
60 Nm
t
Use new screws!
Shock absorber at trailing arm
110
Therefore the vehicle must be positioned on its wheels with the weight load of a person seated on Nm
t
the rear seat.
151
25 Nm
120
Nm
Note
t
t
t
t
t
Never load the wheel bearing if the drive shaft was removed!
If the vehicle should be lowered onto its wheels and moved, the outer joint of a drive shaft must be
temporarily inserted.
Welding and straightening work is not allowed on the bearing and wheel control components of the
wheel suspension.
Self-locking nuts must always be replaced.
Always replace corroded self-locking nuts and screws.
1t
39 Nm
replace after each removal
152
t initially tighten crosswise to 10 Nm, then tighten crosswise to the recommended tightening torque
2Shim
3Assembly carrier
t
removing and installing Chapter
4Drive shaft with inner CV joint
t
removing and installing Chapter
t
repairing Chapter
570 Nm + 90
t
M12 x 1.5 x 80
t
replace after each removal
6Screw
t
M12 x 1.5 x 75
t
replace after each removal
7Top suspension arm
t
removing and installing Chapter
t different versions, assignment Electronic Catalogue of Original Parts
8Guide joint
t
removing and installing Chapter
9Collar screw, 80 Nm
10 Brake carrier with brake caliper
t
repairing Chapter
t
Removing and installing brake pads Chapter
11 10 Nm
12 Self-locking twelve-point nut
t
tighten Chapter
t
replace after each removal
13 4 Nm
14 Brake disc
t Assignment Electronic Catalogue of Original Parts
15 Brake disc, internally ventilated
t Assignment Electronic Catalogue of Original Parts
16 Wheel hub with pulse rotor for wheel speed sensor
t
The pulse rotor is welded with the wheel hub
t
Check axial run-out of pulse rotor Chapter
t
pressing in and pressing out Chapter
17 Circlip
t
replace after each removal
t
pay attention to correct position
18 Wheel bearing
t
pressing in and pressing out Chapter
t
replace, is damaged when pressing out
t The spare part only as a set wheel bearing with mounting parts (- Pos. 12 and - Pos. 17)
19 Cover plate
20 Self-locking nut, 70 Nm + 90
t
replace after each removal
21 Bottom suspension arm
t
removing and installing Chapter
t Assignment Electronic Catalogue of Original Parts
22 Guide joint
t
removing and installing Chapter
153
23 90 Nm
t
replace after each removal
t
insert from the outside of the vehicle
24 Rubber-metal bearing
t
for trailing arm
t
removing and installing Chapter
25 Trailing arm
t
removing and installing Chapter
t The thread -arrow A- for the support of the stop buffer - Pos. 29 is no longer applicable as of 08.99
if it is intended to install the stop buffer - Pos. 30 in the trailing arm before the manufacturing date 08.99,
t
the thread -arrow A- must be bored out to 10.5 mm
26 75 Nm
t
replace after each removal
27 Mount for rear axle
t check the overall track of the rear axle after installation and adjust if necessary
t the track can be corrected by moving the mounting bracket
28 Spacer
t
only on vehicles with rough road suspension
t on vehicles without spacer, none must be subsequently fitted
29 Stop buffer with threaded pin, 10 Nm
t
is no longer inserted as of 08.99
t the stop buffer is delivered as a spare part - Pos. 30
30 Stop buffer with positioning pin
t
as of 08.99
t the correct installation position is determined by the positioning pin
t the positioning pin must be removed on the underside when using vehicles produced before 08.99
t The beginning of the spring coil must lie against the leg -arrowt Fitting position of the coil spring Chapter and Chapter
31 Wheel speed sensor
t
removing and installing Chapter
t insert with solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
32 8 Nm
33 Flange shaft of the rear axle gearbox
t
t
t
t
t
t
t
t
Pressure bushing, e.g. -E-44Bell, e.g. -E-40Pressure plate, e.g. -E-6-1Pressure plate, e.g. -E-13-1Thrust washer, e.g. -E-39- (-VAS 5146-)
Thrust plate -MP 3-467Washer -MP 6-416Extractor -Kukko 18-0Raise vehicle.
Remove wheel.
Removing drive shaft Chapter
Unscrew fixing screws -1- from brake carrier
and remove brake carrier with brake caliper.
Note
155
pump.
Check if all the tools are correctly centred, if
by pumping.
Press out the wheel bearing
156
pump.
Check if all the tools are correctly centred, if
housing.
157
pump.
Check if all the tools are correctly centred, if
158
The shoulder -arrow- of the pressure plate -4must point to the special nut -3-.
Position hollow piston cylinder -1- with tie bolt
pump.
Check if all the tools are correctly centred, if
8 Nm
4 Nm
80 Nm
I
II
10 Nm 39 Nm
120 Nm
50 Nm + 60
t
Always use new nut!
Tightening process Chapter.
Raise vehicle.
Remove wheel.
trailing arm.
Unclip the brake line from the holder.
160
the spindle.
-A- Ring spanner
Insert rubber-metal bearing
spindle.
Install trailing arm
The installation is carried out in the reverse order
Chapter.
If the fitting position of the mounting bracket to
the trailing arm was not marked, the fitting
position must be determined Chapter.
t
t
t
t
Assembly device -MP 5-401Assembly device -MP 5-402Assembly device -T10030Assembly device -T30017WARNING
If the top and bottom guide joint must be replaced, first of all remove the coil spring.
Raise vehicle.
Remove wheel.
the stop.
162
Raise vehicle.
Remove wheel.
163
to the stop.
Fit the socket with two extensions onto the
wheel screw.
Press the extension slightly towards the top
164
165
Raise vehicle.
Remove wheel.
trailing arm.
If necessary, unclip the brake line from the
holder.
166
Raise vehicle.
167
168
169
the body.
Unscrew mounting bracket from body
-arrows-.
Note
Tightening torques:
Brake carrier with brake caliper to trailing arm
Mounting bracket to trailing arm
Bracket to body
Suspension arm to trailing arm
t
Use new screws and nuts!
Shock absorber at trailing arm
Therefore the vehicle must be positioned on its wheels with the weight load of a person
t
seated on the rear seat.
Tighten drive shaft to flange shaft M8 diagonally across in 2 steps (I and II)
t
Use new screws!
Pipe connection of brake line
Wheel bolt
Nut to wheel hub
t
Always use new nut!
Tightening process Chapter.
170
80 Nm
90 Nm
75 Nm
70 Nm +
90
110 Nm
II
10
39
Nm
Nm
14 Nm
120 Nm
50 Nm +
60
WARNING
If the top and bottom suspension arm must be replaced, first of all remove the coil spring.
Raise vehicle.
Remove wheel.
the stop.
171
Tightening torques:
Suspension arm to trailing arm
t
Use new screws and nuts!
Suspension arm to assembly carrier
t
Use new screws and nuts!
70 Nm + 90
70 Nm + 90
Raise vehicle.
Remove wheel.
172
the stop.
Fit the socket with two extensions onto the
wheel screw.
Press the extension slightly towards the top
70 Nm + 90
70 Nm + 90
110 Nm + 90
173
160 Nm
2Cross member
3Rubber-metal bearing for final drive
t
removing and installing Chapter
t Observe fitting position: kidney-shaped openings or arrow must point vertically upwards or downwards
4Rubber-metal bearings for assembly carrier
t are supplied as spare parts in a sealed plastic bag
t do not use any rubber-metal bearings which have been stored openly
t
removing and installing Chapter
t Observe fitting position: ribbed side must point upwards
5110 Nm + 90
t
replace after each removal
6Assembly carrier
t
removing and installing Chapter
7Support for final drive
840 Nm + 45
t
M10 x 40
t
replace after each removal
940 Nm + 45
174
t
M10 x 55
t
replace after each removal
10 Rear final drive
t removing and installing manual gearbox; Rep. gr.39.
11 Self-locking nut, 25 Nm
t
replace after each removal
12 Anti-roll bar
13 20 Nm
t mate both screws and initially tighten to 5 Nm, subsequently tighten
14 Clamp
15 Coupling rod
Raise vehicle.
Remove wheels.
175
Raise vehicle.
176
177
the body.
178
Tightening torques:
Bracket to body
t
Use new screws!
Assembly carrier to body
t
Use new screws!
Propshaft at final drive
Shock absorber at trailing arm
Therefore the vehicle must be positioned on its wheels with the weight load of a person
t
seated on the rear seat.
Pipe connection of brake line
Wheel bolt
Raise vehicle.
Remove wheels.
75 Nm
110Nm +
90
60 Nm
110 Nm
14 Nm
120 Nm
the spindle.
Install
Note
The rubber-metal bearings are supplied as spare
parts in a sealed plastic bag.
Do not use any rubber-metal bearings which
t
have been stored openly!
t
spindle.
-A- Ring spanner
The ribbed side of the rubber-metal bearing
For removing and installing the front rubbermetal bearings on the assembly carrier, the
spindle must be inserted from below.
Further installation occurs in reverse order.
Install assembly carrier with final drive
Chapter.
Bleeding Brake System Chapter.
Setting the hand-brake Chapter.
After installing, check the track and the camber
on the wheel alignment tester, adjust if necessary
Chapter.
Tightening torques:
180
Bracket to body
t
Use new screws!
Assembly carrier to body
t
Use new screws!
Propshaft at final drive
Shock absorber at trailing arm
Therefore the vehicle must be positioned on its wheels with the weight load of a person
t
seated on the rear seat.
Pipe connection of brake line
Wheel bolt
Remove wheels.
181
75 Nm
110Nm +
90
60 Nm
110 Nm
14 Nm
120 Nm
-arrow-.
182
the spindle.
Install
Fitting position of the rubber-metal bearing
spindle.
Install assembly carrier with final drive
Chapter.
183
torque.
4Assembly carrier
Further installation occurs in reverse order.
Bleeding Brake System Chapter.
Setting the hand-brake Chapter.
After installing, check the track and the camber
on the wheel alignment tester, adjust if necessary
Chapter.
Tightening torques:
Bracket to body
t
Use new screws!
Assembly carrier to body
t
Use new screws!
Anti-roll bar to assembly carrier
Propshaft at final drive
Shock absorber at trailing arm
Therefore the vehicle must be positioned on its wheels with the weight load of a person
t
seated on the rear seat.
Cross member for final drive to assembly carrier
Support for final drive to assembly carrier
Pipe connection of brake line
Wheel bolt
184
75 Nm
110Nm +
90
20 Nm
60 Nm
110 Nm
60 Nm
60 Nm
14 Nm
120 Nm
drive.
The further work procedure is now valid again for
both sides.
Release twelve-point nut.
Note
185
186
187
1Outer CV joint
t
must be replaced completely
t
removing Fig.
t install: drive onto the shaft with a plastic hammer until the compressed circlip expands
t
grease Chapter
t
check Chapter
2Circlip
t
replace
t
insert into the groove at the shaft
3Thrust ring
t
Fitting position Fig.
4Disc spring
t
Fitting position Fig.
5Open warm-type clamp
t
replace
t tension with tensioning pliers, e.g. -V.A.G 1682- Fig.
6Joint boot
t
Material: Hytrel (Polyelastomere)
t
inspect for tears and chafing points
7Open warm-type clamp
t
replace
t
tensioning Fig.
8Drive shaft (solid shaft)
t Assignment Electronic Catalogue of Original Parts
939 Nm
t
M8 x 48
10 Shim
188
189
a plastic hammer.
190
t
t
t
t
t
191
192
193
The vehicle must only be aligned using an alignment gauge released by the manufacturer!
It is recommended to align the front and rear axles during each vehicle alignment procedure.
Otherwise correct vehicle driving behaviour cannot be guaranteed!
Note
Only perform a vehicle alignment after the first 1000 to 2000 km to allow the helical springs to fully
settle.
t During adjustment work try to approximate the nominal values.
For vehicles equipped with ESP, the basic setting must be carried out after the axial measurement,
t
function 04, group 060 Chapter.
If the fitting position of the rear axle and hence the running direction of the vehicle are not considered this
could result in a skewed steering wheel.
Removing and installing steering wheel Body Work; Rep. gr.69.
It is necessary to perform a vehicle alignment in the event of:
t
incorrect driving behaviour;
t damage caused by accident and if parts have been replaced;
t
axle parts have been removed;
t
there is unilateral tyre wear.
Front axle part replaced Chassis alignment required Rear axle part replaced Chassis alignment required
yes
no
yes
no
track control arm
X
Shock absorber
X
Wheel-bearing housing
X
Coil spring
X
Track rod/track-rod ends
X
Complete rear axle
X
1)
Steering gear
X
Assembly carrier
X
1)
Assembly carrier
Bottom suspension arm
X
X
Top suspension arm 1)
Suspension strut
X
Trailing arm 1)
X
t
1)
194
Test conditions
l Determine the chassis version according to the vehicle data sticker Chapter.
Check the wheel suspensions, wheel bearing, steering and steering linkage for impermissible play and
l
damage, if necessary repair.
l Check tyre inflation pressure, if necessary correct BookletOctavia or fuel-tank cap sticker.
Check the tyre tread depth. The difference between the left and right tyres on an axle must not exceed 2
l
mm.
l The unladen weight of the vehicle must correspond with the vehicle documents.
Unladen weight: Weight of the vehicle with full fuel tank and full water reservoir for windscreen
wiper/washer and headlamp cleaning system, spare wheel, tool kit, jack and without driver. The spare
wheel, tool kit and jack must be located in the position prescribed by the vehicle manufacturer.
Vehicle must be aligned, with the springs having been repeatedly deflected and having returned to their
l
original position.
l Make sure that during alignment no sliding base and no rotating plate touch the limit stop.
l The steering wheel must be in the posItion required to drive straight ahead .
Very important!
The measuring device must be positioned and adjusted in compliance with the specifications; observe the
l
manufacturer's instructions!
If necessary obtain information on your alignment gauge from the manufacturer.
In the course of time the alignment platform and alignment gauge/alignment computer may deviate from
their original adjustment/setting.
The alignment platform and alignment gauge/alignment computer must be tested and adjusted during a
maintenance operation at least once a year or following the manufacturer's instructions and if necessary be
adjusted!
Treat these precision instruments with great care.
Measurement preliminaries
1238/B-.
Overview of the work sequence for vehicle
alignment
The following sequence of work steps must
always be respected!
Determine what chassis has been mounted in
1 - the vehicle. This information can be found on
the vehicle data sticker Chapter.
Check camber on front axle, if necessary take
2the mean Chapter.
3 - Check camber on rear axle Chapter.
Checking the track on the rear axle, if
4 - necessary taking the mean/adjusting
Chapter.
Vehicles with front-wheel drive: The track of the
195
196
Chassis terms
Nominal values for vehicle alignment
t
t
5.0 mm.
If the deviation is exceeded, e.g. 8,0 mm, correct
the difference on the rear axle on the relevant side
by placing weights in the boot.
Suitable weights are e.g. sand bags approx. 10
kg
Checking the camber on the front axle, if necessary take the mean
197
Tightening torques:
Assembly carrier to body
t
Screw position -1t
Use new screws!
Assembly carrier to body
t
Screw position -2t
Use new screws!
100Nm + 90
100Nm + 90
198
Checking the track on the rear axle, if necessary taking the mean/adjusting
If the values lie outside the tolerance the transversal inclination must be checked and if necessary adjusted
Chapter.
Vehicles with front-wheel-drive
The overall track of the rear axle is not adjustable.
It is only possible to take the mean of the individual track values equally by moving the mounting brackets.
Loosen all screws of the mounting bracket -1-.
Move the bracket of the rear axle -1- in
transverse direction.
-2- Rear axle body
Tighten screws: 30 Nm + 90.
Always use new screws!
If the measured values still lie outside the
tolerance, check the axle body for damage and if
necessary replace.
Vehicles with four-wheel drive
The overall track value of the rear axle is
adjustable.
direction.
2Trailing arm
Tighten screws: 75 Nm.
Always use new screws!
Check the overall track after adjusting the
single track. The overall track must correspond
with the specified nominal value Chapter.
199
If the values lie outside the tolerance the transversal inclination must be checked and if necessary adjusted
Chapter.
Release counternut -1 -.
Adjust track by turning the left and/or right
track rod.
Position open-end wrench on hexagon -arrow-.
Check that the bellows have not become twisted
after turning the track rods!
Twisted bellows wear fast. Bellows replace if
damaged.
Tighten counternut -1- with 50 Nm and again
damaged.
Note
The indicated values are only given as an example.
For track values with the same preceding sign (+/+ or -/-) subtract the smaller value from the greater
201
For safety reasons never change tyres individually but at least in axle pairs.
Tyres with the greatest tread depth must always be fitted at the rear.
It is recommended to fit tyres of the same make, same type and tread pattern on all wheels.
When replacing the disc wheel or the tyre always replace the rubber valve.
Mount the tyre with the DOT marking pointing towards the outside of the wheel. This applies only to the
left side of the vehicle for directional tyres.
For directional tyres mount a wheel/tyre combination for the right side of the vehicle as spare wheel.
Disc wheel
Note
t Because of design variations the disc wheel and wheel trim cap may differ from the figure.
t When using anti-theft wheel bolts, the anti-theft bolt must be as close as possible to the valve.
12t
t
3-
Tyres
Wheel rims
6J x 14 H2, ET38
6J x 15 H2, ET38
Wheel screw, 120 Nm
202
Light-alloy wheel
Because of design variations the light alloy rim and wheel trim cap may differ from the figure.
12t
t
t
345t
67-
Tyres
Light-alloy rim
6J x 15H2, ET38
6.5J x 15 H2, ET43
6.5J x 16 H2, ET42
Wheel screw, 120 Nm
Wheel bolt key
Pull-off shackle
included in tool kit
Cap
Wheel trim cap
203
koda vehicles are equipped, depending upon vehicle equipment, with a spare wheel or a tyre repair set
(BREAKDOWN SET).
Tyre sealant
204
205
Tyre disassembly
A tyre which was filled or sealed with tyre sealant must be cleaned, e.g. with a damp cloth, after detaching it
from the wheel rim (when it is repaired).
WARNING
The tyre sealant must not come in contact with the eyes or the skin.
The tyre sealant is harmful to your health, it can cause eye irritation or allergy.
Wear safety gloves and safety goggles during work.
206
t Tyre sealant or residues of this should not be mixed with other wastes / fluids.
Residues of tyre sealant must be collected and stored in plastic tanks and transferred to the contract dealer
t who is responsable for waste materials. This is also valid for agents with expired best before dates.
Sealant as waste is listed in the waste catalogue under the number 08 04 10 as hazardous waste.
207
The ABS, ABS/EDL are vehicle safety systems; system knowledge is required for working on such
systems.
Faults are indicated by the warning light for the
-ABS K47--1- and the red warning light for the
hand brake/brake fluid level -KU/33--2-.
t
Certain faults are not detected until after a
minimum speed of 20 km/h has been exceeded
(conduct a road test).
If the ABS warning light -K47- and the warning
light for the hand brake/brake fluid level
-K14/33- do not light up and if in spite of this
t
the brake system is not fully operational, look
for the fault in the conventional brake system
Chapter and Chapter.
Notes on rectifying sudden faults Technical
Service Handbook binder Current Flow
t
Diagrams, Electrical Fault Finding and Fitting
Locations
t
208
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
t
Before commencing work on the ABS system it is necessary to interrogate the fault memory in order to
check complaints and conduct specific fault finding.
Do not separate plug connections unless the ignition is switched off.
Before commencing work on the ABS, ABS/EDL, switch off the ignition and disconnect the earth strap at
the battery. On models fitted with a coded radio set, pay attention to the coding; determine if necessary.
Welding work using electric welding equipment may affect the ABS, ABS/EDL system.
Before commencing welding work using electrical welding tool:
Disconnect the terminal from the negative pole of the battery and cover the negative pole, if necessary
remove the battery.
Connect the earth connection of the electric welding tool directly to the part to be welded. There must not
be any electrically insulated parts between the earth connection and the welding point.
Electronic control units and electrical wiring must not touch the earth connection or the welding
electrode.
Do not drive the vehicle if the connector is unplugged from the control unit.
Only carry out work on the hydraulic control unit within the repair measures mentioned here.
When carrying out work on the antilock brake system, ensure scrupulous cleanliness, on no account use
agents containing mineral oils, such as oil, greases, etc.
Thoroughly clean connection points and the surrounding area before disconnecting, but do not use any
aggressive cleaning agents, such as brake cleaner, petroleum, thinner or similar.
Place removed parts on a clean surface and cover.
After separating the control unit/hydraulic unit use the transport protection for valve domes.
Carefully cover or close opened components if the repair is not completed immediately. (Use screw plug
from the repair set SP no. -1 HO 698 311 A-)
Do not use fluffy cloths.
Remove spare parts from their wrapping immediately before fitting.
Use only genuine wrapped parts.
If the system is opened, avoid working with compressed air and avoid moving the vehicle.
Ensure that no brake fluid is able to flow into the connectors.
Observe the current regulations when handling brake fluid Chapter.
After completing work which involved opening the brake system, bleed brake system with brake filling
and bleeding device, e.g. -VAS 5234-, Chapter.
During the subsequent road test, ensure that at least one controlled brake application is performed (pulsing
must be felt on the brake pedal).
209
t Binder Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
t Self-study programme no. 26: vehicle safety - new technical information
t
Technical Service Handbook
210
Distinguishing features of the ABS ITT Mark 20 IE and the ABS/EDL ITT Mark 20 IE
General Instructions
The ABS prevents the wheels from locking during a brake application initiated by the driver.
The electronic differential lock, EDL, is a starting-off aid. A supporting torque is created for the differential
by electronically controlling the braking of the driven wheel which is slipping. The engine power is thus
available for the gripping wheel with the better adhesion. This also applies when reversing.
The brake system is split diagonally. Brake servo assistance is provided pneumatically by the vacuum brake
servo unit.
Vehicles fitted with ABS and ABS/EDL ITT Mark 20 IE do not have a mechanical brake pressure regulator.
Specifically matched software in the control unit, the electronic brake pressure distribution, EBD, regulates
the brake pressure on the rear axle.
The hydraulic pump -V64-, the hydraulic unit -N55- and the control unit -J104- form the hydraulic control
unit. A repair is only possible in the removed condition.
New control units supplied through the Parts Division are not coded. They must be coded after installation
Chapter.
distinguishing features:
t Dimension -A-: 100 mm.
8 valve domes: The protective sleeves for the
t valves are visible if the control unit is separated
from the hydraulic unit Chapter.
Control unit identification. The control unit
version is shown on the display of the vehicle
system tester -V.A.G 1552-. Select function 01
t
interrogate control unit version Chapter.
ABS without CAN BUS ABS with CAN BUS
electronic catalogue of original parts
t Overview of selectable functions Chapter.
211
distinguishing features:
t Dimension -A-: 130 mm.
10 valve domes: The protective sleeves for the
t valves are visible if the control unit is separated
from the hydraulic unit Chapter.
Control unit identification. The control unit
version is shown on the display of the vehicle
system tester -V.A.G 1552-. Select function 01
t interrogate control unit version Chapter.
ABS/EDL without CAN BUS ABS/EDL with
CAN BUS electronic catalogue of original
parts
t Overview of selectable functions Chapter.
212
213
Self-diagnosis
Self-diagnosis functions
214
215
216
Perform self-diagnosis
Test requirements
l Approved tyre size fitted to all wheels; tyres inflated to the specified pressure.
Mechanical/hydraulic part of the brake system together with the brake light switch and brake lights
l
operating properly.
No leaks in hydraulic connections and lines (visual inspection of hydraulic unit, brake calipers, wheel
l
brake cylinders, tandem brake master cylinder).
l
Wheel bearings and wheel bearing play O.K.
l Control unit correctly bolted to the hydraulic unit.
l Plug connection on control unit -J104- correctly plugged in (lock is engaged).
l Inspect plug contacts of ABS components for damage and correct fitting.
l All fuses according to current flow diagram O.K (to check remove fuses from the fuse holder).
l
Supply voltage O.K. (minimum 10.0 V).
Readout on display:
Vehicle system test
If no readout appears in the display, check plug connection for self-diagnosis HELP
Select function XX
- electrical test Chapter and further, test steps 14 and 15.
217
Note
Additional operating instructions can be displayed via the HELP button of
the -V.A.G 1552- according to the program.
t The button is used for moving forward in the program.
Switch on ignition.
Readout on display:
Vehicle system test
Enter 03 for address word Brake electronics and confirm
HELP
Press key.
XXXXX
Note
t
218
HELP
00 01 02 03 04 05 06 07 08 1)
Page
Chapter
Chapter
Chapter
Chapter
Chapter
Chapter
Chapter
Chapter
Chapter
Readout on display:
Enter 02 for the function Interrogate fault memory and confirm
X faults detected!
Press button.
The stored faults are displayed in sequence.
No fault
Note the fault message displayed in the fault table Chapter. For MK60
detected!
Chapter.
If No fault detected, the program returns to its initial position after the button is
pressed:
Readout on display:
End output (function 06) Chapter.
Switch off ignition and disconnected vehicle system
tester.
Note
Vehicle system test
HELP
Select function XX
If a fault is detected:
t
1. Rectify fault (repair)
t 2. Interrogate fault memory (function 02)
t 3. Erase fault memory (function 05)
t 4. End output (function 06)
t
5. Road test
t 6. Interrogate the fault memory again
Note
With the automatic test sequence, all fault memory contents of the control units are interrogated.
Switch on ignition
Readout on display:
Vehicle system test
HELP
Enter 00 for function Automatic test sequence and confirm
Select function XX
entry with key Q.
The control unit identification is shown on the display.
1J0907379 H ABS/EDL 20 IE
->
After this all the control unit identifications with possible entries in the CAN 0001
Coding 13504
fault memories appear in the display.
WSC XXXXX
End output (function 06) Chapter.
Fault table
Note
As the control units are interlinked over a data BUS line, always start fault finding by activating the key
t function 00 Automatic test sequence on all control units fitted to the vehicle. This allows to interrogate
all the control units fitted in the vehicle in order to determine their possible faults.
All the possible faults which can be detected by the ABS control unit -J104- and can be displayed by the
t
-V.A.G 1552-, are listed according to their 5-digit fault code.
t
The fault table may also display the fault type.
t The column Fault elimination refers to certain test steps in the electrical test.
Before replacing components found to be faulty, test all corresponding plug connections, lines and earth
t connections according to the current flow diagram binder Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations
After carrying out the repair, always interrogate and erase the fault memory using the vehicle system
t
tester -V.A.G 1552- and perform a test drive (at a speed above 20 km/h).
t After the test drive interrogate the fault memory again.
Vehicles without CAN BUS
Readout on
Possible cause of fault
Rectifying fault
display
-V.A.G 1552No fault
If after repair No fault detected is displayed, the self-diagnosis is completed. If the ABS
detected
does not operate without fault in spite of the display read-out No fault detected, proceed as
follows: 1. Perform a test drive at a speed above 20 km/h, 2. Interrogate the fault memory
again, if still no fault is stored, 3. continue fault finding without self-diagnosis and perform
the electrical test completely Chapter.
00283
Open circuit, short-circuit to positive or
Inspect wiring and plug connections according
Front left
to earth or loose contact in the wiring
to the current flow diagram binder Current
t
wheel speed
between wheel speed sensor -G47- and
Flow Diagrams, Electrical Fault Finding and
sensor -G47ABS control unit -J104Fitting Locations
Perform electrical Test Chapter.
t
220
Readout on
Possible cause of fault
display -V.A.G
155200283
Open circuit, short-circuit to positive or
Front left wheel to earth or loose contact in the wiring
t
speed sensor
between wheel speed sensor -G47- and
-G47ABS control unit -J104signal outside
the tolerance 1)
Rectifying fault
Damage to the pulse rotor or to the wheel Check the wheel speed sensor -G47- and
t
1)
The type of fault can only be detected as of 20 km/h (perform test drive).
Readout on
Possible cause of fault
Rectifying fault
display -V.A.G
155200285
Open circuit, short-circuit to positive or
Inspect wiring and plug connections
Front right
to earth or loose contact in the wiring
according to the current flow diagram
t
wheel speed
between wheel speed sensor -G45- and binder Current Flow Diagrams,
sensor -G45ABS control unit -J104Electrical Fault Finding and Fitting
Locations
Perform electrical Test Chapter.
t
00285
Front right
speed sensor
-G45signal outside
the tolerance 1)
t
1)
Readout on
display -V.A.G
155200287
Rear right wheel
t
speed sensor
-G44-
Rectifying fault
00287
Open circuit, short-circuit to positive or
Inspect wiring and plug connections
Rear right speed to earth or loose contact in the wiring
according to the current flow diagram
t
t
1)
Readout on
Possible cause of fault
display -V.A.G
155200290
Open circuit, short-circuit to positive or
Speed sensor
to earth or loose contact in the wiring
t
rear left -G46between wheel speed sensor -G46- and
ABS control unit -J104-
Rectifying fault
Damage to the pulse rotor or to the wheel Check the wheel speed sensor -G46- and the
00290
Open circuit, short-circuit to positive or
Rear left wheel
to earth or loose contact in the wiring
t
speed sensor
between wheel speed sensor -G46- and
-G46ABS control unit -J104signal outside
the tolerance 1)
Damage to the pulse rotor or to the wheel Check the wheel speed sensor -G46- and the
mechanical fault
t
1)
1)
Readout on
Possible cause of fault
Rectifying fault
display -V.A.G
155200668
Open circuit, short-circuit to positive
Inspect wiring and plug connections according
t
Onboard
or earth
to the current flow diagram binder Current
voltage tml. 30
Flow Diagrams, Electrical Fault Finding and
signal outside
Fitting Locations
the tolerance
Perform electrical test Chapter and continue.
01044
ABS control unit -J104- incorrectly
Check coding of the ABS control unit -J104t
Control unit
coded
Chapter
wrongly coded
Bridge in the multi-pin connector to
Inspect wiring and plug connections according
the ABS control unit -J104- from
to the current flow diagram binder Current
t
contact 3 to contact 14 interrupted or
Flow Diagrams, Electrical Fault Finding and
short-circuited
Fitting Locations.
Perform electrical test Chapter and
continue.
01130
Electrical malfunctions due to
continue.
If the fault occurs again:
t ABS control unit -J104- defective
Replace ABS control unit -J104- Chapter.
t
01276
Plug connection E-engine to control Performing actuator diagnosis Chapter.
t
ABS hydraulic
unit
pump -V64signal outside
the tolerance 1)
Open circuit, short-circuit to positive
Inspect wiring and plug connections according
t
or earth
to the current flow diagram binder Current
Flow Diagrams, Electrical Fault Finding and
Fitting Locations.
Perform electrical Test Chapter.
t ABS hydraulic pump -V64- defective
224
Readout on display
Possible cause of fault
-V.A.G 155201312
ABS control unit -J104t
Databus drive
incorrectly coded
1)
defective
or
Engine control unit
t
incorrectly coded
t
Databus drive
defective 1)
sporadic
Rectifying fault
01314
Open circuit in the data
Check databus cables and plug connections according
Engine control unit t BUS lines, short-circuit to to the current flow diagram binder Current Flow
no communication
positive or to earth
Diagrams, Electrical Fault Finding and Fitting
Locations
Perform electrical test Chapter and continue.
01315
Open circuit in the data
Check databus cables and plug connections according
Gearbox control
t BUS lines, short-circuit to to the current flow diagram binder Current Flow
unit 2)
positive or to earth
Diagrams, Electrical Fault Finding and Fitting
no communication
Locations
Perform electrical test Chapter and continue.
01316
Open circuit in the data
Check databus cables and plug connections according
Brake control unit t BUS lines, short-circuit to to the current flow diagram binder Current Flow
no communication
positive or to earth
Diagrams, Electrical Fault Finding and Fitting
Locations
Perform electrical test Chapter and continue.
1)
The fault data BUS drive defective does not result in the ABS warning light -K47- or the hand
brake/brake fluid level warning light -K14/33- lighting up. The ABS function is fully maintained.
2)
Only on vehicles with automatic gearbox.
Readout on display
-V.A.G 155218256
Please read out fault
memory of the engine
CU
Rectifying fault
225
65535
Control unit defective
Requirements:
l
Fault memory was interrogated
Press key.
Readout on display:
Enter 05 for the function Erase fault memory and confirm the
Press key.
Readout on display:
Vehicle system test
Note
HELP
Select function XX
Ending output
Enter 06 for the function End output and confirm with the key Q.
Readout on display:
Switch on ignition.
Select function XX
The ABS warning light -K47- and the hand brake/brake fluid level warning
light -K14/33- must go out after approx. 2 seconds.
vehicle.
Connect the vehicle system tester -V.A.G 1552- and enter the address word 03 brake electronics with
Select function XX
entry with key Q.
Readout on display:
Code control unit
Enter the correct code number for the vehicle and confirm
Q
with key Q.
Enter code number XXXXX
(0Table of codes Chapter.
32767)
Table of codes
Code number - model year
Engine identification characters Engine
ABS version 1997
1998
1999
2000 2001
AMD
1,4 Itr./44 kW ABS
03604 03604
AMD
1,4 Itr./44 kW ABS/EDL
03604 03604
AEE
1,6 Itr./55 kW ABS
03604 03604 03604 03604
AEE
1,6 Itr./55 kW ABS/EDL 03604 03604 03604 03604
AEH
1,6 Itr./74 kW ABS
03604 03504 03504 03504
AEH
1,6 Itr./74 kW ABS/EDL 03604 13504 13504 13504
AGN
1,8 Itr./92 kW ABS
03604 03504 03504
AGN
1,8 Itr./92 kW ABS/EDL 03604 13504 13504
AGU
1,8 Itr./110 kW ABS
03304
AQY
2.0 ltr./85 kW ABS/EDL
13504
ARX
1.8 ltr./110 kW 4x4
13504
AGR
1.9 ltr./66 kW 4x4
13504 13504
ATD
1.9 ltr./74 kW 4x4
13504
AZJ
2.0 ltr./85 kW 4x4
13504
Vehicles without CAN BUS
The control unit coding appears in the display, e.g. 03604: 1J0907379 A ABS/EDL ITT AE 20 GI V00 ->
Coding 03604
WSC XXXXX
Vehicles with CAN BUS
The control unit coding appears in the display, e.g.
1J0907379 H ABS/EDL 20 IE CAN 0001
13504:
->
Coding 13504
WSC
Continued for all vehicles
XXXXX
Press key.
Vehicle system
Readout on display:
test
Enter 06 for the function End output and confirm with the key Q.
HELP
Note
Select function XX
227
The ABS warning light -K47- and the hand brake/brake fluid level warning light
t -K14/33- will light up and will remain lit up if the control unit is incorrectly
coded.
There is a simultaneous entry in the fault memory Chapter; interrogate fault
t
memory 02.
If the control unit is coded with an approved code, no fault entry is made in the
t
fault memory and the ABS warning light does not flash.
If the control unit is not coded (Code 00000), the ABS warning light -K47- and
t the hand brake/brake fluid level warning light flash -K14/33- (once per second).
In this case no entry is made in the fault memory.
HELP
confirm the entry with Q.
Select function XX
Test of the wheel speed sensor assignment
Display group number 001:
Readout on display:
Reading measured value block
Enter display group number
Enter 01 for the display group number 01 and confirm entry with
XXX
key Q.
In the measured value block there are always 4 display fields
-arrows- 1 through 4.
wheel by hand.
Display field
1
2
3
4
Denomination
Front left wheel speed (km/h)
Front right wheel speed (km/h)
Rear left wheel speed (km/h)
Rear right wheel speed (km/h)
bearing housing.
Exterior damage to the wheel speed sensor or the pulse rotor (change
t
damaged component).
Test of the brake light switch for the ABS and the ABS/EDL function
Display group number 003
Readout on display:
Enter 03 for the display group number 03 and confirm entry with
key Q.
Test conditions
t Brake pedal not actuated
2
3
4
activated
If the display of the -V.A.G 1552-, despite the foot brake activated -0- or the foot brake not activated -1-,
is:
Actuator diagnosis
230
word 03 brake electronics with the ignition switched on Chapter. Wheel FL/FR block
During the next work steps, the ABS warning light flashes 2 times and the
hand brake/brake fluid level warning light flashes 4 times per second.
Final control diagnosis
- ->
Readout on display:
Hydraulic
pump
ABS
-V64
Press the button within the next 60 seconds.
Readout on display:
Final control diagnosis
- ->
Actuate brake pedal.
Operate brake
Press key.
Readout on display:
Final control diagnosis
Instruct the 2nd mechanic to rotate the relevant wheel by hand.
- ->
If the wheel does not lock, it is possible that there is a fault in the
IFL: 0V OFL: 0V Wheel FL
mechanical/hydraulic part of the brake system.
locked
Press key.
Readout on display:
Press key.
Final control diagnosis
- ->
The ABS hydraulic pump -V64- must run
IFL: 0V OFL: 0V Wheel FL
Brake pedal must not yield.
locked
If the brake pedal yields, there is a fault in the hydraulic unit. If this is
the case replace the hydraulic unit Chapter.
Readout on display:
Instruct the 2nd mechanic to rotate the relevant wheel by hand.
Final control diagnosis
- ->
If the wheel does not lock, it is possible that there is a fault in the
IFL: 0V OFL: VBAT Wheel FL
mechanical/hydraulic part of the brake system.
free
Press key.
ABS hydraulic pump -V64- no longer runs
Readout on display:
Final control diagnosis
Press key.
- ->
Brake pedal must be felt to yield.
IFL: 0V OFL: 0V Wheel FL
If the brake pedal does not yield, there is a fault in the hydraulic unit. If
free
this is the case replace the hydraulic unit Chapter.
Readout on display:
Final control diagnosis
Instruct the 2nd mechanic to rotate the relevant wheel by hand.
- ->
If the wheel does not lock, it is possible that there is a fault in the
IFL: 0V OFL: 0V Wheel FL
mechanical/hydraulic part of the brake system.
locked
Press key.
Final control diagnosis
- ->
Readout on display:
231
Press key.
Readout on display:
Final control diagnosis
- ->
Actuate brake pedal.
Release brake
Press key.
Readout on display:
Press key.
Final control diagnosis
- ->
The ABS hydraulic pump -V64- must run.
IFR: 0V OFR: 0V Wheel FR
Brake pedal must not yield.
locked
If the brake pedal yields, there is a fault in the hydraulic unit. If this is
the case replace the hydraulic unit Chapter.
Readout on display:
Final control diagnosis
Press key.
- ->
Brake pedal must be felt to yield.
IFR: 0V OFR: 0V Wheel FR
If the brake pedal yields, there is a fault in the hydraulic unit. If this is
free
the case replace the hydraulic unit Chapter.
Readout on display:
Final control diagnosis
Instruct the 2nd mechanic to rotate the relevant wheel by hand.
- ->
If the wheel does not lock, it is possible that there is a fault in the
IFR: 0V OFR: 0V Wheel FR
mechanical/hydraulic part of the brake system.
locked
Press key.
Readout on display:
Final control diagnosis
- ->
Take your foot off the brake pedal.
Release brake
Press key.
Readout on display:
Final control diagnosis
- ->
Actuate brake pedal
Operate brake
Press key.
Readout on display:
Final control diagnosis
Instruct the 2nd mechanic to rotate the relevant wheel by hand.
- ->
If the wheel does not lock, it is possible that there is a fault in the
IRL:0V ORL:0V
Wheel RL
mechanical/hydraulic part of the brake system.
locked
Press key.
Readout on display:
Press key.
Final control diagnosis
- ->
The ABS hydraulic pump -V64- must run.
IRL:VBAT ORL:0V
Wheel RL
Brake pedal must not yield.
locked
If the brake pedal yields, there is a fault in the hydraulic unit. If this is
the case replace the hydraulic unit Chapter.
Readout on display:
Instruct the 2nd mechanic to rotate the relevant wheel by hand.
Final control diagnosis
- ->
If the wheel locks, it is possible that the brake pressure lines to the
IRL:VBAT ORL:VBAT
Wheel RL
wheel brakes are wrongly connected.
free
Press key.
ABS hydraulic pump -V64- no longer runs.
Readout on display:
Final control diagnosis
Press key.
- ->
Brake pedal must be felt to yield.
IRL:VBAT ORL:0V
Wheel
If the brake pedal does not yield, there is a fault in the hydraulic unit. If
RL free
this is the case replace the hydraulic unit Chapter.
Final control diagnosis
Readout on display:
-
232
->
Press key.
Readout on display:
Final control diagnosis
- ->
Take your foot off the brake pedal.
Release brake
Press key.
Readout on display:
Final control diagnosis
- ->
Actuate brake pedal
Operate brake
Press key.
Readout on display:
Final control diagnosis
Instruct the 2nd mechanic to rotate the relevant wheel by hand.
- ->
If the wheel does not lock, it is possible that there is a fault in the
IRR:0V ORR:0V
Wheel RR
mechanical/hydraulic part of the brake system.
locked
Press key.
Readout on display:
Press key.
Final control diagnosis
- ->
The ABS hydraulic pump -V64- must not run.
IRR:VBAT ORR:0V
Wheel RR
Brake pedal must not yield.
locked
If the brake pedal yields, there is a fault in the hydraulic unit. If this is
the case replace the hydraulic unit Chapter.
Readout on display:
Instruct the 2nd mechanic to rotate the relevant wheel by hand.
Final control diagnosis
- ->
If the wheel locks, it is possible that the brake pressure lines to the
IRR:VBAT ORR:VBAT
Wheel RR
wheel brakes are wrongly connected.
free
Press key.
ABS hydraulic pump -V64- no longer runs.
Readout on display:
Final control diagnosis
Press key.
- ->
Brake pedal must be felt to yield.
IRR:VBAT ORR:0V
Wheel
If the brake pedal does not yield, there is a fault in the hydraulic unit. If
RR free
this is the case replace the hydraulic unit Chapter.
Readout on display:
Final control diagnosis
Instruct the 2nd mechanic to rotate the relevant wheel by hand.
- ->
If the wheel does not lock, it is possible that there is a fault in the
IRR:0V ORR:0V
Wheel RR
mechanical/hydraulic part of the brake system.
locked
Press key.
Readout on display:
Final control diagnosis
- ->
Take your foot off the brake pedal.
Release brake
Press key.
Read-out on display: (for vehicles with EDL)
Instruct the 2nd mechanic to rotate the relevant wheel by hand.
Final control diagnosis
If the wheels do not lock, there is a fault in the hydraulic part of the ABS - ->
EDL valves/ Hydr.p:VBAT
system. If this is the case replace the hydraulic unit Chapter.
Wheel FL/FR block.
Press key.
The ABS warning light -K47- goes out.
Function unknown or cannot
- ->
Readout on display:
be
carried
out
at
the
moment
Note
The final control diagnosis is completed
233
Press key.
Readout on display:
Note
If the ABS warning light does not go out, there is a fault in the
t
system.
Carefully follow the test sequence step by step: first interrogate the
t
fault memory, then erase.
Basic setting
Enter 001
Enter display group number XXX
Confirm the entry with the key Q.
Readout on display:
System in basic setting
t
Pedal yields.
Depress pedal and hold...
t Hydraulic pump starts running.
t
Pedal moves back.
System in basic setting
Readout on display:
Release pedal;FR+FL bleeder screws
Press button.
OPEN
Note
234
Press button.
Readout on display:
System in basic setting
t
Pedal yields.
Depress pedal and hold...
t Hydraulic pump starts running.
t
Pedal moves back.
System in basic setting
3
Readout on display:
Release pedal;FR+FL bleeder screws OPEN
Press button.
System in basic setting
Readout on display:
Please wait . . . (10 sec.)
t Hydraulic pump starts running.
System in basic setting
2
Readout on display:
Actuate
pedal
10x;
Bleeder
screws
CLOSED
Press button.
Readout on display:
System in basic setting
t
Pedal yields.
Depress pedal and hold...
t Hydraulic pump starts running.
t
Pedal moves back.
System in basic setting
5
Readout on display:
Release
pedal;FR+FL
bleeder
screws
OPEN
Press button.
System in basic setting
Readout on display:
Please wait . . . (10 sec.)
t Hydraulic pump starts running.
System in basic setting
6
Readout on display:
Actuate
pedal
10x;
Bleeder
screws
CLOSED
Press button.
Readout on display:
System in basic setting
t
Pedal yields.
Depress pedal and hold...
t Hydraulic pump starts running.
t
Pedal moves back.
System in basic setting
7
Readout on display:
Release
pedal;FR+FL
bleeder
screws
OPEN
Press button.
System in basic setting
Readout on display:
Please wait . . . (10 sec.)
t Hydraulic pump starts running.
System in basic setting
8
Readout on display:
Actuate
pedal
10x;
Bleeder
screws
CLOSED
Press button.
Readout on display:
System in basic setting
t
Pedal yields.
Depress pedal and hold...
t Hydraulic pump starts running.
t
Pedal moves back.
System in basic setting
9
Readout on display:
Release
pedal;FR+FL
bleeder
screws
OPEN
Press button.
System in basic setting
Readout on display:
Please wait . . . (10 sec.)
t Hydraulic pump starts running.
System in basic setting
10
Readout on display:
Actuate pedal 10x; Bleeder screws CLOSED
Press button.
Readout on display:
System in basic setting
t
Pedal yields.
Depress pedal and hold...
t Hydraulic pump starts running.
t
Pedal moves back.
235
10
11
Readout on display:
14
14
Readout on display:
12
Readout on display:
12
17
236
16
HELP
Q
HELP
Test conditions
The fuses must be OK in compliance with the current flow diagram binder Current Flow Diagrams,
l Electrical Fault Finding and Fitting Locations To check, remove fuses from the fuse holder on the
battery and the fuse holder on the left of the dash panel.
Before starting the test switch off the ignition and electrical consumers (headlights, lighting, blowers
l
etc.).
Note
All unlisted contacts are not yet assigned and must under no circumstances be connected to other
components!
237
Contac
Wiring to component ...
t
1
Front left speed sensor -G472
Front left speed sensor -G473
Jumper to contact -144
Voltage supply terminal -155
Rear left wheel speed sensor -G466
Rear left wheel speed sensor -G467
Plug connection -T16a/7 K- - cable
8
Earth terminal 31
9
Voltage supply of battery +
10
Data BUS cable (CAN-L) binder Current Flow Diagrams, Electrical Fault Finding and Fitting
Locations
11
Data BUS cable (CAN-H) binder Current Flow Diagrams, Electrical Fault Finding and Fitting
Locations
14
Jumper to contact 3
16
ABS warning light
18
Brake light switch -F19
Front right speed sensor -G4520
Front right speed sensor -G4522
Rear right wheel speed sensor -G4423
Rear right wheel speed sensor -G4424
Left earth point under battery
25
Voltage supply of battery +
238
239
Test table
The denominations of the bushes of the test box -V.A.G 1598/21- are identical to the contact
t denominations of the ABS control unit -J104- in the current flow diagram binder Current Flow
Diagrams, Electrical Fault Finding and Fitting Locations
If the measured values deviate from the nominal values, perform the fault eliminating measures listed in
t
the right part of the table.
t Once these values are reached, additionally check the cables for short-circuit to positive and earth.
t Electrical continuity tests with the measuring tool set -V.A.G 1594 A- (bridge structure).
If the measured values only differ slightly from the specified values, clean the bushes and plugs of the
test devices and measuring cables (e.g. with contact spray) and repeat test. Before replacing the relevant
t
components test the cables and connections more specifically for nominal values below 10 , repeat the
resistance measurement on the component.
Switch on measuring range: voltage measurement (20 V =)
Test -V.A.G
Test covers
Specified Measures for deviations from nominal
Test
l
step 1598/21value
conditions value
bushes
additional
works
1
8 + 25 Voltage supply of the l Ignition off 10.0-14.5V Test wiring of contact 8 to earth.
ABS hydraulic pump
Test wiring of contact 25 via the
-V64- to the ABS
240
9 + 24
4+8
8 + 18
Voltage supply of the l Ignition off 10.0-14.5V Test wiring of contact 24 to earth.
valves in the ABS
Test wiring of contact 9 via the fuse
hydraulic unit -N55- to
to battery positive binder
works
5
19 + 20 Resistance of the l Ignition off 1,0 ... 1.3
Disconnect plug connection on speed
contact).
If the lines are not found to be faulty:
Replace speed sensor -G45- Chapter.
6
1 +2
Resistance of the
front left speed
sensor -G47-
k
sensor -G47-.
Test the wiring according to the current
flow diagram binder Current Flow
Diagrams, Electrical Fault Finding and
Fitting Locations
241
22 + 23
Resistance of the
rear right speed
sensor -G44-
k
sensor -G44-.
Test the wiring according to the current
flow diagram binder Current Flow
Diagrams, Electrical Fault Finding and
Fitting Locations
Throughout the test, move cables (loose
contact).
If the lines are not found to be faulty:
Replace speed sensor -G44- Chapter.
5+6
Resistance of the
rear left speed
sensor -G46-
k
sensor -G46-.
Test the wiring according to the current
flow diagram binder Current Flow
Diagrams, Electrical Fault Finding and
Fitting Locations
Throughout the test, move cables (loose
contact).
If the lines are not found to be faulty:
Replace speed sensor -G46- Chapter.
bushes
works
9
19 + 20 Voltage signal l Vehicle raised
Check the installation of the wheel
of the front
speed sensor -G45- and the pulse
l Ignition off
right speed
rotor.
sensor -G45Turn front right Alternating
Check wheel speed sensor -G45- to
voltage min.
wheel by
ensure it is correctly connected
1
65
mV
approx. 1 /s
read measured value block,
Chapter, display group number
001
10
1+2
Voltage signal l Vehicle raised
Check the installation of the wheel
of the front left l Ignition off
speed sensor -G47- and the pulse
speed sensor
rotor.
-G47Turn front left Alternating
Check wheel speed sensor -G47- to
voltage min.
wheel to
ensure it is correctly connected
65 mV
approx. 1 1/s
read measured value block,
Chapter, display group number
001.
11
22 + 23 Voltage signal l Vehicle raised
Check the installation of the wheel
242
12
5+6
Voltage signal
of the rear left
speed sensor
-G46-
l Vehicle raised
l Ignition off
Turn rear left
wheel to
approx. 1 1/s
Alternating
voltage min.
190 mV
works
13
3+14
Jumper l Ignition off 0.0 - 1.0 Check the cables and the contacts in the plug
binder Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
If there is a deviation from the specified value:
Replace jumper.
-T16a-1)
A- with the measuring
tool set -V.A.G 1594 A- to
-T16a-1)
Contact 4 - earth
contact 16 - positive
1)
Chapter, contact assignment of the plug connection for the voltage supply and the self-diagnosis with
the vehicle system tester -V.A.G 1552-.
Switch on measuring range: resistance measurement (200 )
Test -V.A.G
Test covers
l Test conditions
step 1598/21 additional works
243
bushes
15
-
Resistance of the l
max. 1.5
Ignition off
Check the cables of
-K- cable for
-T16a/7- via wiring
Disconnect the multi-pin plug
-V.A.G 1552-, connection from the ABS
-Diagnose - an Kontakt 7
plug connection
binder Current Flow
control unit -J104-.
-16a-1)
Diagrams, Electrical Fault
Connect test box V.A.G
1)
Chapter, contact assignment of the plug connection for the voltage supply and the self-diagnosis with
the vehicle system tester -V.A.G 1552-.
Functional test: ABS warning light -K47Test -V.A.G
Test covers
Test
l
step 1598/21conditions
bushes
additional
works
16
Function of l Ignition on
the ABS
warning light
-K47-
Specified value
Functional test: Hand brake/brake fluid level warning light -K14/33Test -V.A.G
Test covers
Specified value
Test
l
step 1598/21conditions
bushes
additional
works
17
_
Function of the
Brake fluid The warning light
l
hand brake/brake
level O.K. -K14/33- lights up
fluid level warning l Ignition on for approx. 2
light -K14/33seconds and goes
out
244
switch -F9-.
Test brake fluid level warning
contact -F34- in the cap
Measures for
deviations from
nominal value
Chapter,
Perform actuator
Hydraulic pump
diagnosis.
starts running
without fault (max.
Replace ABS
10 secs.)
control unit -J104 Chapter
Hydraulic pump
does not run
Replace hydraulic
unit -N55 Chapter
1598/21-.
max. 1.5 Test the wiring according to the
Check the data BUS cable
Remove fuse.
1)
1-
Brake servo unit with master brake cylinder and brake fluid reservoir
2t
t
t
3t
4-
1)
for about 2 seconds after the ignition is switched on or the engine is started
5-
if hand-brake is applied
6-
Pulse rotor for the wheel speed sensor at the rear on the right and left
check Chapter
removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter and Chapter
7t
t
8t
check Chapter
247
removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter
Removing and installing the hydraulic control unit and the bracket
Note
Make absolutely sure that no brake fluid gets into the plug connector housing of the control
unit. This may result in the corrosion of the contacts and to system failure. Carefully clean
out the plug connector housing with compressed air if it gets dirty.
Special tools and workshop equipment required
t
t
t
Vehicle system tester -V.A.G 1552Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3CBrake pedal arrester, e.g. -V.A.G 1238/B-
t
t
248
1t
the hydraulic pump -V64-, the hydraulic unit -N55- and the ABS control unit -J104- form the
hydraulic control unit.
t
t
2-
the hydraulic control unit must be removed and installed as a whole unit
repairing Chapter
Brake line, 14 Nm
t between the master brake cylinder/floating piston circuit and ABS hydraulic unit
3t
4t
5t
6t
7-
Brake line, 14 Nm
ABS hydraulic unit to front left brake caliper
Brake line, 14 Nm
ABS hydraulic unit to wheel cylinder/rear right brake caliper
Brake line, 14 Nm
ABS hydraulic unit to wheel cylinder/rear left brake caliper
Brake line, 14 Nm
ABS hydraulic unit to front right brake caliper
Brake line, 14 Nm
t between master brake cylinder/push rod piston circuit and hydraulic unit
249
8-
t
t
25-pin
do not disconnect the plug connector before the self-diagnosis is complete, switch off the
ignition before disconnecting the plug connector
9-
Self-locking nut, 20 Nm
10 -
Support
11 -
Dowel screw, 8 Nm
12 -
Cap nut, 25 Nm
Before disconnecting the battery determine the code of radio sets fitted with anti-theft
coding.
re-set clock,
Disconnect battery.
Note
The following 2 work steps do not apply to the 1.6 ltr./55 kW engine:
250
251
252
Chapter.
Unscrew nuts -1- and cap nut -3-.
Install
Installation is carried out in the reverse
order.
Tightening torques:
Nuts to body: 20 Nm
Use new nuts!
Cap nut to body: 25 Nm
Disassembly and assembly of the hydraulic control unit is described on an ABS unit. The
work procedure for the other versions of the ABS ITT Mark 20 IE is identical Chapter.
The repair of the hydraulic control unit is carried out by separating the ABS control unit
-J104- from the hydraulic unit -N55- which is connected to the hydraulic pump -V64-. The
defective component is replaced.
Disassembling the hydraulic control unit
Disconnect the plug for the hydraulic pump motor from the control unit.
254
During the removal of the control unit -bmake sure that the valve domes of the
hydraulic unit -a- do not tilt along with the
solenoid coils of the control unit.
255
256
Checking/removing and installing parts of the ABS system on the front axle
Special tools and workshop equipment required
t Wiring loom repair kit, e.g. Skoda Car Tool Kit koda, Order No.: S 504 500 V
t
Raise vehicle.
Separate plug connection of wheel speed
sensor/wheel speed sensor cable -arrow-.
Release screw -2-.
Take the wheel speed sensor -G45- /
-G47- out of the wheel bearing housing.
Install
Clean the inner surface of the hole before
inserting the wheel speed sensor and
coat with a solid lubricant paste -G 000
650-.
Raise vehicle.
Remove wheel.
257
Raise vehicle.
Remove wheel.
set clock,
Disconnect battery.
Note
259
260
Contact
19 + 20
1 +2
22 + 23
5+6
Install
Draw in new wheel speed sensor cable.
261
Checking/removing and installing parts of the ABS system on the rear axle (disc brake and
drum brake) - front-wheel drive
Special tools and workshop equipment required
t Wiring loom repair kit, e.g. Skoda Car Tool Kit koda, Order No.: -S 504 500 Vt
Remove and install wheel speed sensor (disc brake - front-wheel drive)
Removing
Raise vehicle.
Install
Clean the inner surface of the hole before
inserting the wheel speed sensor and
coat with a solid lubricant paste -G 000
650-.
Raise vehicle.
Remove wheel.
Note
set clock,
Disconnect battery.
Raise vehicle.
Remove wheel.
123
Pulse rotor
Wheel speed sensor
Wheel speed sensor screw
265
266
Removing and installing as well as adjusting brake light switch up to model year 1999
Special tools and workshop equipment required
t
267
Removing and installing as well as adjusting brake light switch as of model year 2000
268
Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder
for vehicles with ABS, ABS/EDL Mark 20
Note
t The hydraulic control unit must be removed and installed completely Chapter.
t
Repairing Chapter.
t Generally tighten the brake line pipe screws to a tightening torque of 14 Nm.
269
1t
2t
Screw cap
with integrated brake fluid level warning contact -F34-
3-
4-
Sealing ring
t
567t
replace
Self-locking nut, 20 Nm
Retaining pin
Master brake cylinder
cannot be repaired, replace completely in the event of faults
8t
Self-locking nut, 20 Nm
only for vehicles with 74 kW, 92 kW and 110 kW engine
270
9t
Heat shield
only for vehicles with 74 kW, 92 kW and 110 kW engine
10 -
Cap nut, 25 Nm
11 12 13 -
8 Nm
Dampening rubber
Support
14 -
Self-locking nut, 20 Nm
15 -
16 17 t
21 -
Brake line
22 t
20 -
19 t
18 t
Brake line
271
Self-diagnosis of the ABS/EDL for four-wheel drive vehicles with Haldex coupling
The self-diagnosis for four-wheel drive vehicles with Haldex coupling is almost identical for
vehicles with ABS/EDL.
Note
Only the differences to the normal ABS/EDL system are described in the self-diagnosis.
Characteristic feature of four-wheel drive vehicles with the Haldex coupling
A longitudinal acceleration sender is positioned in the ABS system -G251-.
t
t
The longitudinal acceleration sender must be switched off for checking the brake system on a
roller type test stand -G251- Chapter, initiate basic setting, display group number 040.
The reactivation of the longitudinal acceleration sender -G251- is performed by switching the
ignition off and on once.
All four-wheel drive vehicles with Haldex coupling are fitted with the EDL (electronic
differential lock).
273
Fault table for the ABS/EDL of four-wheel drive vehicles with Haldex coupling
Readout on display
-V.A.G 155201279
Longitudinal
acceleration sender
-G251electrical fault in the
circuit
Rectifying fault
Longitudinal acceleration
sender -G251- defective
01279
Longitudinal
acceleration sender
-G251implausible signal
Longitudinal acceleration
sender -G251- defective
01324
Open circuit, short-circuit to
Four-wheel drive control t positive or earth in the data
unit -J492- no
BUS lines
communication
Enter 006 display group number 006 and confirm with Enter display group number XXX
key Q.
Reading measured value block 6
0.00 m/s2
Readout on display:
Display
field
1
Test conditions
->
+ 0.5m/s2
not assigned
not assigned
not assigned
275
Readout on display:
Display field
Test conditions
t
t
Connection available
no connection
t
t
Connection available
no connection
t
t
Connection available
no connection
not assigned
t
t
t
Read fault memory of the control units connected to the data BUS
Engine control unit
Gearbox control unit (only for automatic gearbox)
Four-wheel drive control unit.
Test the wiring according to the current flow diagram binder Current Flow Diagrams,
Electrical Fault Finding and Fitting Locations
276
The display group number 040 is required for switching off the longitudinal acceleration
sender -G251-, e.g. to check the brake system on a roller type test stand Chapter.
The display group number 069 is required for the null balance of the longitudinal
acceleration sender -G251- Chapter.
Note
The reactivation of the longitudinal acceleration sender -G251- is performed by switching the
ignition off and on once.
Note
No Login procedure is performed for switching off the longitudinal acceleration sender.
Display group number: 040
Readout on display:
Basic setting
HELP
Enter 0, 4 and 0 for the display group number 040 and confirm with Enter display group number
key Q.
XXX
Note
The Login procedure must be first of all performed for the null balance. To do so first enter the
workshop code in the vehicle system tester -V.A.G 1552-.
Display group number 069
Readout on display:
Vehicle system test
HELP
Enter 11 for the function Login procedure and confirm
Select function XX
with Q.
Login procedure
Readout on display:
Enter code number XXXX
Enter code number 40168 and confirm with key Q.
Readout on display:
Vehicle system test
Select function 04 for Initiate basic setting and confirm entry HELP
Select function XX
with key Q.
277
HELP
Readout on display:
Basic setting
HELP
Enter 069 for the display group number 069 and confirm the entry with Enter display group number
the key Q.
XXX
Press .
Readout on display:
Vehicle system test
HELP
Electrical test of the ABS/EDL for four-wheel drive vehicles with Haldex coupling
Electrical test ABS/EDL Chapter.
Multi-pin plug connection with contact assignment Chapter.
Additional contact assignment of the multipin plug connection -T25- wiring loom/ABS
control unit -J104-
Contact
13
15
17
Test table
Test steps 1 to 19 Chapter
The denominations of the bushes of the test box -V.A.G 1598/21- are identical to the
t contact denominations of the ABS control unit -J104- in the current flow diagram binder
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
t
If the measured values deviate from the nominal values, perform the fault eliminating
measures listed in the right part of the table.
Once these values are reached, additionally check the cables for short-circuit to positive
and earth.
t Electrical continuity tests with the measuring tool set -V. A. G 1594 A- (bridge structure).
If the measured values only differ slightly from the specified values, clean the bushes and
plugs of the test devices and measuring cables (e.g. with contact spray) and repeat test.
t Before replacing the relevant components test the cables and connections more
specifically for nominal values below 10 , repeat the resistance measurement on the
component.
Test V.A.G
Test covers
ste 1598/21
p
bushes
20
Test conditions
additional works
Cables for
l
Ignition off
longitudinal
acceleration l Set measuring range 200
sender -G251- Disconnect the electrical plug
connection from the
longitudinal acceleration
sender -G251 Disconnect the multi-pin
connector -T25a- from the
279
max.
Check the cables between
the multi-pin connector of the 1.5
longitudinal acceleration
280
12t
t
t
3t
4t
t
1)
1)
5t
Hand brake/brake fluid level warning light -K14/33Fitting location: in the dash panel insert, function:
if hand-brake is applied
6-
Pulse rotor for the wheel speed sensor at the rear on the right and left
check Chapter
removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter.
7t
8-
Pulse rotor for the wheel speed sensor at the front on the right and left
check Chapter
removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter.
9-
t
t
Fitting location: on the central pipe to the right, near the right pillar -Aremoving and installing Chapter
Remove the glove compartment in the dash panel Body Work; Rep. gr.70.
Install
Checking/removing and installing parts of the ABS system on the rear axle (disc brake) - fourwheel drive
Special tools and workshop equipment required
t Wiring loom repair kit, e.g. Skoda Car Tool Kit koda, Order No.: S 504 550 V
t
Removing and installing wheel speed sensor on the rear axle (disc brake) - four-wheel drive
Removing
Raise vehicle.
283
Install
Clean the inner surface of the hole before
inserting the wheel speed sensor and
coat the wheel speed sensor with a solid
lubricant paste -G 000 650-.
Raise vehicle.
Remove wheel.
284
Tightening torques:
Brake carrier with brake caliper to trailing arm
Wheel bolts
65 Nm
120 Nm
Remove and install the wheel speed sensor cables (four-wheel drive)
Note
t
t
re-set clock
Disconnect battery.
Raise vehicle.
Remove wheel.
286
288
The ABS/EDL/ESP is a vehicle security system; system knowledge is required for working
on such systems.
t Binder Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
t
Technical Service Handbook
t Self-study programme no. 26 vehicle safety - new technical information
t Self-study programme no. 28 electronic stability program, basis, construction, function
289
Distinguishing features of the ABS/EDL ITT Mark 20 IE and the ABS/EDL/ESP ITT Mark 20 IE
General Instructions
The ABS prevents the wheels from locking during a brake application initiated by the driver.
The electronic differential lock, EDL, is a starting-off aid. A supporting torque is created for the differential
by electronically controlling the braking of the driven wheel which is slipping. The engine power is thus
available for the gripping wheel with the better adhesion. This also applies when reversing.
A description of the structure and function of the ABS and the EDL can be found in self-study programme
No. 26.
The electronic stability program -ESP- recognises critical driving conditions and stabilises the vehicle by
individual wheel braking and by intervention in the engine control. This occurs independently of a brake or
accelerator pedal activation.
The ESP is active over the entire speed range. If the ESP is in regulating mode, the ESP warning lights flash
three times per second.
The description of the structure and function of the ESP can be found in self-study programme No. 28.
The brake system is split diagonally. Brake servo assistance is provided pneumatically by the vacuum brake
servo unit.
Vehicles fitted with ABS/EDL/ESP ITT Mark 20 IE do not have a mechanical brake pressure regulator.
Specifically matched software in the control unit, the electronic brake pressure distribution, EBD, regulates
the brake pressure on the rear axle.
The hydraulic pump -V64-, the hydraulic unit -N55- and the control unit -J104- form the hydraulic control
unit. A repair is only possible in the removed condition.
New control units supplied through the Parts Division are not coded. They must be coded after installation.
t
t
291
As the control units are interlinked over a data BUS line, always start fault finding by interrogating the
contents of the fault memories of all the control units fitted to the vehicle.
The interrogation of the fault memory is performed with the key function 00 Automatic test sequence.
When doing so check whether a possibly stored fault might affect the ABS system.
Self-diagnosis relates to the electrical/electronic part of the ABS, i. e. faults are detected only over the
electrical connection to the control unit (e.g. open circuit of a wheel speed sensor).
The 47-pin ABS control unit -J104- together with the hydraulic unit forms a compact unit. The unit is
located in the left of the engine compartment. The control unit is equipped with a fault memory. The
connection for self-diagnosis is located in the storage compartment on the driver's side.
The control unit detects faults during the operation of the vehicle and stores them in a permanent memory,
whose information is retained even if the battery voltage is disconnected.
Faults which occur sporadically (isolated) are likewise detected and stored. If this fault which affects the
data BUS system no longer occurs during 15 vehicle starts and driving-off procedures or 50 vehicle starts
and driving-off procedures and if the fault does no longer reappear with other faults, it is erased from the
fault memory (fault delete counter) with the exception of the fault control unit defective.
After the ignition is switched on and/or the engine is started, the ABS warning lights -K47-, the red warning
light for the hand brake/brake fluid level -K14/33- and the ESP warning light -K155- flash for approx. 2
seconds.
During this period a test sequence (self-check) is performed in the control unit with the following functions:
t
Test of supply voltage, min. 10.0 V
t
Test of control unit including valve coils.
t
Check of control unit coding
t Static test of the wheel speed sensor (without speed signal)
After a start-up, should it appear that the speed signal is not O.K as of approx. 20 km/h, the ABS warning
t
light lights up again -K47-.
Initiate self-diagnosis at the start of fault finding and retrieve the stored information using the vehicle
system tester -V.A.G 1552- or the fault read-out scan tool -V.A.G 1551-.
Note
The following description only relates to the vehicle system tester -V.A.G 1552- using the current
program card.
The use of the fault reader -V.A.G 1551- with integrated printer is similar. A minor deviation on the
t
display read-out is possible.
t To end the self-diagnosis or to switch to another address word select function 06 End output.
t Identify the faults displayed by referring to the fault table and subsequently carry out the fault elimination.
t
292
Pos. Denomination
1
WARNING
Once the ABS warning light -K47- and the hand brake/brake fluid level warning light -K14/33have lit up, then the rear wheels can already lock when braking lightly.
Overview
Meaning
ESP warning
light -K155-
lights up
lights up
lights up
does not
light up
lights up
System O.K.
does not
light up
does not
light up
ESP intervention
does not
light up
flashes
lights up
lights up
293
lights up
lights up
lights up
does not
light up
lights up
does not
light up
Warning light -K47If the ABS warning light (-K47-) -1- does
not go out after the ignition is switched
t on and after completion of the test
sequence, the causes of the fault may
be:
-a- the supply voltage is less than 10 V
-b- an ABS fault is present
The antilock braking system is switched off
if an ABS fault -b- is present. The EBD
function (Electronic Brake pressure
Distribution) is furthermore active while the
conventional brake system remains fully
operational. Interrogate the fault memory
Chapter.
-c- a sporadic fault existed on a wheel
speed sensor after the last vehicle start
In case of a wheel speed sensor fault -c-,
the ABS warning light goes out
automatically -K47- after restarting the
vehicle and after a speed above 20 km/h is
reached.
-d- The line of the ABS control unit -J104for operating the ABS warning light -K47- in
the dash panel insert -J218- is interrupted
binder Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
-e- Dash panel insert defective
294
Warning light -K47- and -K14/33If the ABS warning light goes out (-K47-)
-1- but the warning light for the hand
brake/brake fluid level (-K14/33-) -2t
remains lit and 3 warning tones are
audible, the following can be the causes
of the fault:
-a- the brake fluid level is too low
-b- the hand-brake is still applied
-c- the switch -F9- for the warning light
-K14/33- is defective or incorrectly adjusted
-d- a fault in the operation of the hand
brake/brake fluid level warning light
-K14/33- binder Current Flow Diagrams,
Electrical Fault Finding and Fitting
Locations.
If the ABS warning light (-K47-) -1- and
the hand brake/brake fluid level warning
t light (-K14/33-) -2- light up, then the ABS
system and the EBD (Electronic Brake
pressure Distribution) have failed.
If the ABS warning light (-K47-) -1- and
the hand brake/brake fluid level warning
light (-K14/33-) -2- light up and 3 warning
t
tones are audible, then the ABS and the
EBD (Electronic Brake pressure
Distribution) have failed.
Note
295
Warning light -K155If the ESP warning light (-K155-) -3- does
not go out after the ignition is switched
t on and after completion of the test
sequence, the causes of the fault may
be:
There is a fault which exclusively effects
the ESP. The ABS/EDL and EBD safety
systems on the vehicle remain fully
functional. Interrogate the fault memory
Chapter.
-a- Short circuit to positive in ESP button
-E256-b- Short circuit to earth in the operation of
the ESP warning light -K155-c- the line for operating the ESP warning
light -K155- is interrupted binder
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations
-d- the ESP system was switched off using
the ESP button -E256If the ESP warning light lights up -K155- for
approx. 100 milliseconds after switching on
the ignition, a coding without ESP control
was entered.
Code the control unit Chapter.
If the ESP warning light -K155- flashes
while driving, the ESP system is operating
in regulating mode.
Warning light -K47-, -K14/33- and -K155If the ABS warning light (-K47-) -1- and
the hand brake/brake fluid level warning
t light (-K14/33-) -2- flash and the ESP
warning light (-K155-) -3- remains lit, the
control unit is not yet coded.
Code the control unit Chapter.
296
Vehicle system tester -V.A.G 1552Diagnostic cable -V.A.G 1551/3- or -V.A.G 1551/3 A-
297
Handheld multimeter, e.g. -V.A.G 1526 AMeasuring tool set -V.A.G 1594/A-
for which the self-diagnosis does not indicate the fault source. In this case the full electric
inspection must be carried out.
for which the self-diagnosis gives a direct indication of the fault source. Then only perform
the test steps recommended in the fault table (targeted approach).
Test conditions
l
Before starting the test switch off the ignition and electrical consumers (headlights,
lighting, blowers...).
Fuses S13, S15, S162, S163 must be O.K. binder Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations To check, remove fuses from the fuse holder.
Note
The following 2 work steps do not apply to the 1.6 ltr./55 kW engine.
Remove air filter
Screw out screws -2- at the air filter -3and lay it aside.
298
All unlisted contacts are not yet assigned and must under no circumstances be connected to
other components!
299
Conta
ct
Control unit with display unit for radio and navigation (only for navigation system)
300
Jumper to contact 18
10
11
12
13
14
not assigned
15
16
17
18
Jumper to contact 8
19
Data BUS cable binder Current Flow Diagrams, Electrical Fault Finding and Fitting
Locations
20
Data BUS cable binder Current Flow Diagrams, Electrical Fault Finding and Fitting
Locations
21
not assigned
22
23
24
TCS/ESP button -E256- / voltage supply relay for warning light -K155-
25
26
27
28
29
30
not assigned
31
32
33
34
35
Control unit with display unit for radio and navigation (only for navigation system)
36
37
38
not assigned
39
40
41
42
43
44
45
not assigned
46
47
1)
Brake detection switch ESP -F83- is identical to release switch of the solenoid coil for
brake pressure -F84-.
Jumper
302
Resistance of the -K- cable for the self-diagnosis, plug connection -T16a- - Perform test step 28
1)
The brake detection switch -F83- is identical to the release switch of the solenoid coil for
brake pressure -F84-.
303
Test table
Notes for the test table
The denominations of the bushes of the test box -V.A.G 1598 A- with adapter -V.A.G
1598/33- are identical to the contact denominations of the control unit -J104- in the current
t
flow diagram binder Current Flow Diagrams, Electrical Fault Finding and Fitting
Locations
If the measured values deviate from the specified values, perform the fault eliminating
t measures listed in the right part of the table binder Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
t Electrical continuity tests with the measuring tool set -V.A.G 1594 A- (bridge structure).
If the measured values only differ slightly from the specified values, clean the bushes and
plugs of the test devices and measuring cables (e.g. with contact spray -G 000 700 04-) and
t repeat test. Before replacing the relevant components test the cables and connections
more specifically for nominal values below 10 , repeat the resistance measurement on the
component.
Test steps 1 - 20
Test steps 21 - 28 Chapter
Switch on measuring range: voltage measurement (20 V =)
Test -V.A.G
Test covers
step 1598 Abushes
14.5V
-T47a/16- via fuse -S162- to
battery positive.
Ignition
off
Fitting Locations
3
14.5V
-T47a/44- via fuse S13 and
ignition starter switch.
Test wiring of contact
-T47a/46- to earth binder
23 + 46 Brake
light
switch
-F-
Test conditions
additional works
Ignition off
0,0-0,5
If necessary set brake light switch
V
Chapter.
Brake
light
switch
-F-
Measuring range
200 set
max.1.5
20 M set
23 + 46 Brake light
suppression
relay -J508-
additional
works
l Ignition on
Brake
l pedal
actuated
31 + 15
Bridge
bushes 31
and 15
0,0-0,5
V
8 + 18
Table of l
codes
Test conditions
additional works
Ignition off
Detach multi-pin connector
-T47aConnect test box -V.A.G 1598
A- with adapter -V.A.G
1598/33-
306
3+4
Test covers
additional
works
Resistance of the
Ignition
l
front right speed
off
sensor -G45-
1,0 ...
Separate plug connection on speed
1.3 k
sensor.
33 + 34 Resistance of the
Ignition
l
front left speed
off
sensor -G47-
1,0 ...
Separate plug connection on speed
1.3 k
sensor.
7+6
Resistance of the
Ignition
l
rear right speed
off
sensor -G44-
1,0 ...
Separate plug connection on speed
1.3 k
sensor.
307
10
37 + 36 Resistance of the
Ignition
l
rear left speed
off
sensor -G46-
1,0 ...
Separate plug connection on speed
1.3 k
sensor.
works
approx. 1 turn
connected and read measured
per sec.
value block Chapter, display
group number 001
Alternating
Check the installation of the
voltage min. wheel speed sensor and the
65 mV
pulse rotor.
13
Alternating
Check the installation of the
voltage min. wheel speed sensor and the
190 mV
pulse rotor.
Alternating
Check the installation of the
voltage min. wheel speed sensor and the
190 mV
pulse rotor.
Check wheel speed sensor -G46to ensure it is correctly
l Test conditions
additional works
Specified
value
Function
of the ABS
warning
l
light -K47-
The warning
The fault memory
was interrogated and light -K47lights up for
there is no fault in
the fault memory of approx. 2
the ABS control unit seconds and
goes out
-J104again
l Ignition off
The multi-pin
connector is inserted
l on the ABS control
unit -J104- and
locked
Switch on ignition
Functional test: Hand brake/brake fluid level warning light -K14/33Test -V.A.G Test covers
ste 1598
p
Abushes
16
Test
conditions
additional
works
Specified
value
Function of the
Brake fluid
l
hand
level is O.K.
brake/brake
l Ignition off
309
fluid level
warning light
-K14/33-
Multi-pin
connector
inserted on
l
control unit
-J104- and
locked
Switch on
ignition
works
The warning
light -K155lights up for
approx. 2
seconds and
goes out
Switch on
ignition
Functional test: Warning light for TCS/ESP button -E256- in test step 18; voltage supply (20
310
additional
works
p
bushes
18
The warning
light -K155lights up for
approx. 2
seconds and
goes out again
The multi-pin
connector is
l inserted on the
ABS control unit
-J104- and locked
Switch on
ignition
Operate TCS/ESP Warning light
-K155- comes
button
on
18a 15 + Function of
Switch off
24 the
ignition
TCS/ESP
Pull out the multibutton
pin connector
-E256from the ABS
control unit -J104-
Switch on
ignition
Button -E256-
8,0 - 14,5V
311
l Test conditions
additional works
steering angle
sender at the plug
connection -T6w
19a
Cables for
steering angle
sender -G85-
Measuring range
200 set
adapter -V.A.G
1598/33
Wiring of contact
-T6w/3- (steering
Wiring of contact
T6w/1 to earth
Measuring range
20 M set
Test conditions
additional works
Cables for
l
Ignition off
lateral
Measuring range 200
acceleration
l
set
sender -G200
acceleration sender)
with contact -T47a/40(control unit)
Wiring of contact
-T3n/2- (lateral
acceleration sender)
with contact -T47a/9(control unit)
Wiring of contact
-T3n/3- (lateral
acceleration sender)
with contact -T47a/25(control unit)
l
max.
1.5
Measuring range
20 M set
Remove fuse S13
Check cables for shortcircuit to positive or to
earth
314
Test steps 21 - 28
Switch on measuring range: resistance measurement (200 )/(20 M)
Test V.A.G
Test
step 1598 A covers
bushes
21
Test conditions
additional works
Cables for l
Ignition off
yaw rate
Measuring range 200
sender
l
set
-G202Pull out the multi-pin
connector -T47a- from
the ABS control unit
-J104-.
Connect test box
-V.A.G 1598 A- with
adapter -V.A.G
1598/33Disconnect the plug
connection -T3m- from
the yaw rate sender
-G202
Wiring of contact
-T3m/1- (yaw rate
sender) with contact
-T47a/42- (control unit)
max.
1.5
Wiring of contact
-T3m/2- (yaw rate
sender) with contact
-T47a/11- (control unit)
Wiring of contact
-T3m/3- (yaw rate
sender) with contact
-T47a/27- (control unit)
l
Measuring range
20 M set
Remove fuse S13
Cables for
brake
pressure
sender 1
-G201-
l
l
Test conditions
additional works
Ignition off
Measuring range 200
set
Pull out the multi-pin
connector -T47a- from the
ABS control unit -J104Connect test box -V.A.G
1598 A- with adapter
-V.A.G 1598/33-
Measuring range 20 M
set
circuit to positive or to
earth
Cables for
brake
pressure
sender 2
-G214-
l
l
Test conditions
additional works
Ignition off
Measuring range 200
set
Pull out the multi-pin
connector -T47a- from the
ABS control unit -J104Connect test box -V.A.G
1598 A- with adapter
-V.A.G 1598/33-
317
Measuring range 20 M
set
Remove fuse S13
Test conditions
additional works
Cables for
l
Ignition off
solenoid coil
l Measuring range 200 set
for brake
pressure
Pull out the multi-pin
318
max.
1.5
Disconnect multi-pin
connector T14c
Test conditions
additional works
Brake
l
Ignition off
detection
l Measuring range 200 set
switch
-F83Pull out the multi-pin
p
bushes
Test conditions
additional works
26 19+20 Data l
Ignition off
BUS
cables l Measuring range 200 set
Disconnect the multi-pin plug
connections from the control
units connected to a data BUS
line (connection in the dash
panel wiring loom -A122- and
-A121-)
1)
Test conditions
additional works
1)
Contact assignment of the plug connection for the voltage supply and the self-diagnosis
with the vehicle system tester -V.A.G 1552- Chapter
l Test conditions
additional works
max.
Test wiring of contact -T16a/7
1.5
to contact -T47a/39-
Measuring range
20 M set
322
1-
Brake servo unit with master brake cylinder and brake fluid reservoir
Release switch of the solenoid coil for brake pressure -F84-; This switch is identical to the
brake detection switch ESP -F83-.
Solenoid coil for brake pressure in the brake servo unit -N247-
The solenoid coil for brake pressure in the brake servo unit -N247- is tested by selfdiagnosis
2t
t The brake pressure sender 1 and the brake pressure sender 2 are equal parts
t The fitting location for the brake pressure sender 1 can also be the Pos. 3 for the brake
323
pressure sender 2
t
3-
t The brake pressure sender 2 and the brake pressure sender 1 are equal parts
t
The fitting location for the brake pressure sender 2 can also be the Pos. 2 for the brake
pressure sender 1
4-
Cable duct
5-
Solenoid coil for brake pressure in the brake servo unit -N247-
6t
Lateral acceleration sender -G200Fitting location: next to the steering column under the dash panel
is checked by self-diagnosis
7t
Yaw rate sender -G202Fitting location: next to the steering column under the dash panel
is checked by self-diagnosis
8t
Fitting location: on the steering column between the steering wheel and the steering
column switch
t
9t
t
10 t
t
is checked by self-diagnosis
ESP warning light -K155Fitting location: in the dash panel insert
function Chapter
Hand brake/brake fluid level warning light -K14/33Fitting location: in the dash panel insert
function Chapter
324
11 t
function Chapter
12 -
t
t
is checked by self-diagnosis
Pulse rotor for the wheel speed sensor at the rear on the right and left
check Chapter
removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter and Chapter
13 t
check Chapter
removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter
14 t
Voltage supply relay for warning light -K155--J535Fitting location: additional relay carrier, space 7
15 t
Diagnostic connection
16 t
17 -
t
t
t
is checked by self-diagnosis
Check the multi-pin plug connection to the control unit Chapter
Do not disconnect the multi-pin plug connection before the self-diagnosis is complete.
switch off the ignition before disconnecting the plug connector.
18 t
t
t
the hydraulic unit -N55- consists of the hydraulic pump -V64- and the valve block with the
inlet and exhaust valves
is checked by self-diagnosis
when changing the hydraulic unit, absolutely close the old part with a plug from the
mounting part kit; SP no. Electronic Catalogue of Original Parts
Remove and install hydraulic control unit (hydraulic unit -N55- with control unit -J104-)
Chapter
t
t
Do not separate the hydraulic pump -V64- from the valve block.
Repairing the hydraulic control unit Chapter
Removing and installing the hydraulic control unit ABS/EDL/ESP and the bracket
Note
Make absolutely sure that no brake fluid gets into the plug connector housing of the control
unit. This may result in the corrosion of the contacts and to system failure. Carefully clean
out the plug connector housing with compressed air if it gets dirty.
Special tools and workshop equipment required
t
t
t
t
t
Mounting part kit, SP no. Electronic Catalogue of Original Parts The mounting part kit
consists of a plug and a protective cap
Brake filling and bleeding device, e.g. -VAS 5234Extraction bottle (commercially available)
Brake fluid Chapter
326
1t
t
47-pin
do not disconnect the plug connector before the self-diagnosis is complete, switch off the
ignition before disconnecting the plug connector
2t
the hydraulic pump -V64-, the ABS hydraulic unit -N55- and the ABS control unit -J104- form
the hydraulic control unit
t the hydraulic control unit must be removed and installed completely Chapter.
t
3t
4t
5t
6t
repairing Chapter
Brake line, 14 Nm
between master brake cylinder/floating piston circuit and hydraulic unit
Brake line, 14 Nm
ABS hydraulic unit to front left brake caliper
Brake line, 14 Nm
ABS hydraulic unit to rear right brake caliper
Brake line, 14 Nm
ABS hydraulic unit to wheel cylinder/rear left brake caliper
327
7t
Brake line, 14 Nm
ABS hydraulic unit to front right brake caliper
8-
Brake line, 14 Nm
t between master brake cylinder/push rod piston circuit and hydraulic unit
9-
Self-locking nut, 20 Nm
10 -
Support
11 -
Dowel screw, 8 Nm
12 -
Cap nut, 25 Nm
Before disconnecting the battery determine the code of radio sets fitted with anti-theft
coding.
set clock,
Disconnect battery.
Note
The following 2 work steps do not apply to the 1.6 ltr./55 kW engine:
328
Release the multi-pin connector -1- (arrow a-) and disconnect it from the
hydraulic control unit (-arrow b-).
Note
329
330
331
332
Install
Installation is carried out in the reverse
order.
Tightening torques:
Nuts to body
t
20 Nm
25 Nm
Mounting part kit, SP no. Electronic Catalogue of Original Parts. The mounting part kit
consists of a plug and a protective cap
333
334
The protective cap -1- and the plugs -2t and -3- are component parts of the
mounting part kit.
The plugs and the protective cap of the
newly installed hydraulic units can be
t
used instead of thoses from the mounting
part kit.
Checking/removing and installing parts of the ABS system on the front axle
Special tools and workshop equipment required
t Wiring loom repair kit, e.g. Skoda Car Tool Kit koda, Order No.: -S 504 500 Vt
336
t
t
set clock,
Disconnect battery.
Note
The following 2 work steps do not apply to the 1.6 ltr./55 kW engine:
Release the multi-pin connector -1- (arrow a-) and disconnect it from the ABS
control unit -arrow b-.
Contact
3+4
33 + 34
6+7
36 + 37
Press out the relevant contacts using a suitable ejection tool from the wiring loom repair
kit.
Release plug connection on wheel speed sensor and separate plug connector.
Install
339
340
Checking/removing and installing parts of the ABS system on the rear axle (disc brake and
drum brake) - front-wheel drive
Removing and installing parts of the ESP system
The description of the structure and function of the ESP can be found in self-study
programme No. 28.
t
t
Remove and install yaw rate sender -G202- and lateral acceleration sender -G200 Chapter
Remove and install steering angle sender -G85- Chapter
Vehicle system tester -V.A.G 1552Diagnostic cable -V.A.G 1551/3- or -V.A.G 1551/3A-
Remove and install yaw rate sender -G202- and lateral acceleration sender -G200The removal and installation procedure of the yaw rate sender -G202- and the lateral
acceleration sender -G200- is the same except for the direct replacement of the sender to be
removed.
Note
Before disconnecting the battery determine the code of radio sets fitted with anti-theft
coding.
set clock,
Disconnect battery.
341
342
Remove the yaw rate sender (-G202-) -1from the bracket -3-.
-2- Lateral acceleration sender -G200Insert the new yaw rate sender (-G202-)
-1- into the bracket -3- and align it
straight.
343
Tightening torques:
Yaw rate sender (-G202-)
9 Nm
20 Nm
Removing and installing steering angle sender -G85Special tools and workshop equipment required
t
t
Vehicle system tester -V.A.G 1552Diagnostic cable -V.A.G 1551/3- or -V.A.G 1551/3ANote
Before disconnecting the battery determine the code of radio sets fitted with anti-theft
coding.
set clock,
Disconnect battery.
345
-3- Housing
346
Carefully release catch hooks -arrowsand remove housing -1- with steering
angle sender -G85- and coil spring.
Install
Slide housing -1- with steering angle
sender -G85- and coil spring onto the
steering column and lock into position
with steering column switch -arrows-.
347
Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder
for vehicles with ABS/EDL/ESP Mark 20
Note
t The hydraulic control unit must be removed and installed completely Chapter.
t
Repairing Chapter.
t Generally tighten the brake line pipe screws to a tightening torque of 14 Nm.
t
The complete master brake cylinder and brake servo unit can be replaced independently of
one another.
348
1-
check Chapter
2-
Self-locking nut 28 Nm
3-
Gasket
4t
Bellows
pay attention to correct position, risk of suction noises
5-
Holder
6t
Screw cap
with integrated brake fluid level warning contact -F34-
7-
8-
Sealing ring
replace
9-
Retaining bracket
10 t
11 t
t
13 t
t
14 t
Retaining pin
fit through the master brake cylinder
12 t
Plugs
15 t
Connector
16 -
Wiring loom
17 -
Self-locking nut, 20 Nm
18 -
Heat shield
19 -
Cap nut, 25 Nm
20 -
Dowel screw, 8 Nm
21 -
Dampening rubber
22 -
Support
23 -
Self-locking nut, 20 Nm
24 -
25 -
26 -
27 t
28 t
30 -
Brake line, 14 Nm
31 t
29 -
Brake line, 14 Nm
32 33 t
t
Plugs
Vacuum hose
with non-return valve
insert in brake servo unit.
350
351
General Instructions
Chapter.
The control unit version appears in the display of -V.A.G 1552-. Select function 01 interrogate
control unit version Chapter. electronic catalogue of original parts
t
1)
352
1-
Brake servo unit with master brake cylinder and brake fluid reservoir
2t
t
t
3t
4t
t
1)
for about 2 seconds after the ignition is switched on or the engine is started
5-
if hand-brake is applied
353
6-
Pulse rotor for the wheel speed sensor at the rear on the right and left
check Chapter
removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter and Chapter
7t
8t
removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter
Removing and installing the hydraulic control unit and the bracket
Note
Make absolutely sure that no brake fluid gets into the plug connector housing of the control
354
unit. This may result in the corrosion of the contacts and to system failure. Carefully clean
out the plug connector housing with compressed air if it gets dirty.
Special tools and workshop equipment required
t
1t
the hydraulic pump -V64-, the hydraulic unit -N55- and the ABS control unit -J104- form the
hydraulic control unit.
t the hydraulic control unit must be removed and installed completely Chapter
t the connections of the brake lines are embedded on the hydraulic control unit
t
2-
repairing Chapter
Support
355
3-
Nut, 20 Nm
4-
8 Nm
5t
Brake line, 14 Nm
Hydraulic unit to wheel cylinder/rear left brake caliper
6t
Brake line, 14 Nm
Hydraulic unit to wheel cylinder/rear right brake caliper
7-
t
t
47-pin
Do not disconnect the plug connection before the self-diagnosis is complete. switch off the
ignition before disconnecting the plug connector.
8-
Brake line, 14 Nm
t between master brake cylinder/push rod piston circuit and hydraulic unit
9-
Brake line, 14 Nm
10 t
Brake line, 14 Nm
11 t
Brake line, 14 Nm
Hydraulic unit to front right brake caliper
t
t
Before disconnecting the battery determine the code of the radio sets fitted with anti-theft
coding.
After connecting the battery, check the vehicle equipment:
on vehicles with radio encoding, carry out the coding,
set clock,
Disconnect battery.
Note
The following 2 work steps do not apply to the 1.4 ltr./55 kW engine:
356
358
The components of the hydraulic control unit are fitted together and connected by 2
screws.
Before removing the Torx screws, secure the hydraulic pump against unintentional
separation from the hydraulic pump with adhesive tape.
t The hydraulic pump and the hydraulic unit constitute a replacement part.
WARNING
The hydraulic pump must not be separated from the hydraulic unit.
359
1-
Torx screws, 8 Nm
2-
Hydraulic unit
The hydraulic unit consists of: -a- Hydraulic pump for ABS or ABS/TCS/EDL -V64--b- Hydraulic
unit for ABS or ABS/TCS/EDL -N55t
t after separating them from the control unit, fit on the transport protection for valve domes
3t
t
when removing them from the hydraulic unit, the valve domes of the hydraulic unit must
not tilt along with the solenoid coils of the control unit
Cover the solenoid coils with a non-fluffing cloth
When assembling the control unit and the hydraulic unit make sure the valve domes of the
hydraulic unit do not tilt along with the solenoid coils of the control unit.
Checking/removing and installing parts of the ABS system on the front axle
Chapter.
Removing and installing the wheel speed sensor cables
Removing
Note
t
t
t
set clock,
initialise power windows on vehicles fitted with power windows.
Disconnect battery.
Note
The following 2 work steps do not apply to the 1.4 ltr./55 kW engine:
361
362
Contact
Wiring to component
33 + 34
45 + 46
42 + 43
36 + 37
Press out the relevant contacts using a suitable ejection tool from the wiring loom repair
kit.
Release plug connection on wheel speed sensor and separate plug connector.
Install
363
Checking/removing and installing parts of the ABS system on the rear axle (disc brake and
drum brake) - front-wheel drive
Chapter.
Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder
ABS/EDL/TCS Mark 60
Note
t The hydraulic control unit must be removed and installed completely Chapter.
t
Repairing Chapter.
t Generally tighten the brake line pipe screws to a tightening torque of 14 Nm.
364
1t
2t
3t
4-
Sealing ring
replace
Screw cap
with integrated brake fluid level warning contact -F34Brake fluid reservoir
5t
6-
Plugs
moisten with brake fluid and press in expansion reservoir
Retaining pin
7-
8-
Self-locking nut, 20 Nm
t
9t
replace
Brake line
Master brake cylinder/push rod piston circuit THV to hydraulic unit
365
10 t
Brake line
11 t
Self-locking nut, 20 Nm
only fitted on certain models
replace
12 t
Heat shield
only fitted on certain models
13 t
repairing Chapter
14 t
Support
with rubber insulation
15 -
16 -
8 Nm
Handheld multimeter, e.g. -V.A.G 1526 AMeasuring tool set -V.A.G 1594 ATest box -V.A.G 1598 AAdapter e.g. -V.A.G 1598/36-
The test steps as of page Anchor apply only for vehicles with ABS/EDL/TCS
t
Vehicles for which the final control diagnosis does not indicate the fault source. In this case
the full electric inspection must be carried out.
Vehicles for which the final control diagnosis does give a direct indication of the fault
t source. Then only perform the test steps recommended in the fault table (targeted
approach).
An overview of all the test steps of the electrical test can be found on the page Chapter.
Test requirements
366
Before starting the test switch off the ignition and electrical consumers (headlights,
lighting, blowers etc.).
The fuses must be OK (to check, remove fuses from the fuse holder) binder Current
Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Remove the protective housing for relays from the cable duct.
367
Earth
Voltage supply of the valves in the hydraulic unit -N55- to the control unit - Perform test step
-J1042
Voltage supply (ignition starter switch) to the control unit -J104-
16
Voltage supply for -V.A.G 1551-, plug connection -T16a-
Jumper
Test table
Notes for the test table
The denominations of the bushes of the adapters -V.A.G 1598/36- are identical to the
t contact denominations of the ABS control unit -J104- in the current flow diagram binder
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
If the measured values deviate from the specified values, perform the fault eliminating
t measures listed in the right part of the table binder Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations.
t Electrical continuity tests with the measuring tool set -V.A.G 1594 A- (bridge structure).
If the measured values only differ slightly from the specified values, clean the bushes and
plugs of the test devices and measuring cables (with contact spray -G 000 700 04-) and
t repeat test. Before replacing the relevant components test the cables and connections
more specifically for nominal values below 10 , repeat the resistance measurement on
the component.
Switch on measuring range: voltage measurement (20 V =)
Test -V.A.G
step 1598 Abushes
Test covers
Test
conditions
Specified
value
additional
works
10.0 14,5V
10.0 14,5V
4 + 47 Voltage supply
l Ignition on
370
l Ignition off
Brake
l pedal not
actuated
approx.
Check brake light switch -F
battery
Chapter.
voltage
Brake
pedal
actuated
Test covers
5 33 + 34 Resistance of
the front right
speed sensor
-G45-
l Test conditions
additional
works
l Ignition off
Specified
value
1.0...1.3 k
6 45 + 46 Resistance of
the front left
speed sensor
-G47-
t Ignition off
1.0...1.3 k
Chapter.
7 42 + 43 Resistance of
the rear right
speed sensor
-G44-
t Ignition off
1.0...1.3 k
8 37 + 36 Resistance of
the rear left
speed sensor
-G46-
t Ignition off
1.0...1.3 k
9 33 + 34 Voltage signal
of the front
right speed
sensor -G45-
l Vehicle raised
l Ignition off
65 mV
approx. 1 turn
connected and read measured
per sec.
value block Chapter, display
group number 001.
190mV
approx. 1 turn
per sec.
11 42 + 43 Voltage signal
of the rear
right speed
l Vehicle raised
l Ignition off
372
sensor -G44-
190mV
approx. 1 turn
per sec.
190mV
approx. 1 turn
per sec.
Functional test: ABS warning light -K47Test -V.A.G Test covers Test
l
step 1598 Aconditions
bushes
additional
works
13
Function of
the ABS
warning
light -K47-
Specified value
Ignition
off
Functional test: Hand brake/brake fluid level warning light -K14/33Test -V.A.G
step 1598 Abushes
14
Test covers
Test
conditions
additional
works
Specified
value
373
l Ignition on
Functional test: Function of the TCS button -E132Test -V.A.G Test covers Test
l
step 1598 Aconditions
bushes
additional
works
15
Function of l Ignition on
the TCS
button
-E132
TCS button
-E132operated
Specified value
bushes
16
11
or
15
Specifie
d value
Test conditions
additional works
Data l
Ignition off
BUS
cables l Measuring range 200
set
Disconnect the multi-pin
plug connections from the
control units connected to
a data BUS line:
Connect -V.A.G 1598 Awith adapter -V.A.G
374
1598/36
max.
1.5
1)
Test covers
Test conditions
additional works
Voltage supply l
Ignition off
for -V.A.G
Connect the handheld
1552-, plug
multimeter -V.A.G 1526connection
1)
with the measuring tool
-T16aset -V.A.G 1594- to the
plug connection -T16a-1)
10.0 14,5V
Test covers
Test conditions
additional works
Resistance of l
Ignition off
the K cable for
-V.A.G 1552-, Disconnect the multi-pin plug
connection from the control
375
plug
connection
-T16a-1)
1)
2)
max.
1.5
19
Test covers
Specifie
Test
conditions d value
additional
works
14 + 38 Jumper for
Ignition
t
ABS/EDL/TCS
off
376
1)
377
1-
2t
3t
4t
5t
Fitting location: on the steering column between the steering wheel and the steering
column switch
6-
function Chapter
7-
function Chapter
8-
function Chapter
9t
check Chapter
removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter and Chapter
10 -
11 t
Diagnostic connection
12 t
adjust Chapter
13 t
t
t
t
is checked by self-diagnosis
Check the multi-pin plug connection to the control unit Chapter
Do not disconnect the multi-pin plug connection before the self-diagnosis is complete.
switch off the ignition before disconnecting the plug connector.
14 t
the hydraulic unit -N55- consists of the hydraulic pump -V64- and the valve block with the
inlet and exhaust valves
when changing, absolutely close the old part with a plug from the mounting part kit; SP no.
Electronic Catalogue of Original Parts
Remove and install hydraulic control unit (hydraulic unit -N55- with control unit -J104 Chapter
Do not separate the hydraulic pump -V64- from the valve block.
15 t
check Chapter
removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter
16 t
t
Fitting location: on the central pipe to the right, near the right pillar -Aremoving and installing Chapter
1)
380
1-
2t
3t
Fitting location: next to the steering column under the dash panel
4-
Fitting location: on the steering column between the steering wheel and the steering
column switch
5t
function Chapter
6-
function Chapter
7-
function Chapter
8-
Pulse rotor for the wheel speed sensor at the rear on the right and left
check Chapter
removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter and Chapter
Brake vacuum pump -V192-1)
9t
only on vehicles with automatic gearbox in combination with the limit values of exhaust gas
according to EU-4
t
t
10 t
Diagnostic connection
11 t
adjust Chapter
12 t
t
13 t
the hydraulic unit -N55- consists of the hydraulic pump -V64- and the valve block with the
inlet and exhaust valves
when changing, absolutely close the old part with a plug from the mounting part kit; SP no.
Electronic Catalogue of Original Parts
Remove and install hydraulic control unit (hydraulic unit -N55- with control unit -J104 Chapter
Do not separate the hydraulic pump -V64- from the valve block.
14 t
check Chapter
removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter
15 t
only RHD 4x4 vehicles on the central pipe to the right, near right pillar -A-
383
384
Pos.
Denomination
WARNING
Once the ABS warning light -K47- and the hand brake/brake fluid level warning light -K14/33have lit up, then the rear wheels can already lock when braking lightly.
Overview
Meaning
ESP warning
light -K155-
lights up
lights up
lights up
does not
light up
lights up
System O.K.
does not
does not
385
light up
light up
ESP intervention
does not
light up
flashes
lights up
lights up
lights up
lights up
lights up
does not
light up
lights up
does not
light up
Warning light -K47If the ABS warning light (-K47-) -1- does
not go out after the ignition is switched
t on and after completion of the test
sequence, the causes of the fault may
be:
-a- the supply voltage is less than 10 V
-b- an ABS fault is present
The antilock braking system is switched off
if an ABS fault -b- is present. The EBD
function (Electronic Brake pressure
Distribution) is furthermore active while the
conventional brake system remains fully
operational. Interrogate the fault memory
Chapter.
-c- a sporadic fault existed on a wheel
speed sensor after the last vehicle start
In case of a wheel speed sensor fault -c-,
the ABS warning light goes out
automatically -K47- after restarting the
vehicle and after a speed above 20 km/h is
reached.
-d- the connection from the ABS control
unit -J104- to the dash panel insert -J218- is
interrupted binder Current Flow
Diagrams, Electrical Fault Finding and
Fitting Locations
-e- Dash panel insert defective
386
Warning light -K47- and -K14/33If the ABS warning light goes out (-K47-)
-1- but the warning light for the hand
brake/brake fluid level (-K14/33-) -2t
remains lit and 3 warning tones are
audible, the following can be the causes
of the fault:
a-
b-
387
Warning light -K155If the ESP warning light (-K155-) -3- does
not go out after the ignition is switched
t on and after completion of the test
sequence, the causes of the fault may
be:
There is a fault which exclusively effects
the ESP. The ABS/EDL and EBD safety
systems on the vehicle remain fully
functional. Interrogate the fault memory
Chapter.
a-
b-
t
t
Handheld multimeter, e.g. -V.A.G 1526 AMeasuring tool set -V.A.G 1594/A-
for which the self-diagnosis does not indicate the fault source. In this case the full electric
inspection must be carried out.
for which the self-diagnosis gives a direct indication of the fault source. Then only perform
the test steps recommended in the fault table (targeted approach).
Test requirements
Chapter
Note
The following 2 work steps do not apply to the 1.6 ltr./55 kW engine.
Remove air filter
Chapter
Contact assignment of the plug connection
-T47a- wiring loom/ABS control unit -J104Note
Fitting Locations
16 -
Earth
17 -
not assigned
20 -
21 a 23 -
not assigned
not assigned
not assigned
not assigned
42 - Rear right wheel speed sensor -G4443 - Rear right wheel speed sensor -G4445 - Front left wheel speed sensor -G4746 - Front left wheel speed sensor -G4747 -
Earth
Jumpers
Resistance of the -K- cable for the self-diagnosis, plug connection -T16a- - Perform test step 25
Test table
392
Note
The denominations of the bushes of the test box -V.A.G 1598 A- with adapter -V.A.G
1598/36- are identical to the contact denominations of the ABS control unit -J104- in the
t
current flow diagram binder Current Flow Diagrams, Electrical Fault Finding and Fitting
Locations
If the measured values deviate from the specified values, perform the fault eliminating
t measures listed in the right part of the table binder Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
t Electrical continuity tests with the measuring tool set -V.A.G 1594 A- (bridge structure).
If the measured values only differ slightly from the specified values, clean the bushes and
plugs of the test devices and measuring cables (with contact spray -G 000 700 04-) and
t repeat test. Before replacing the relevant components test the cables and connections
more specifically for nominal values below 10 , repeat the resistance measurement on
the component.
Switch on measuring range: voltage measurement (20 V =)
Test -V.A.G
step 1598 Abushes
Test covers
Specifie
Test
conditions d value
additional
works
l
Ignition
off
Ignition
on
393
41 + 47 Brake
light
switch
-F-
l
l
Specifie
d value
Ignition off
0.0 - 0.5
V
4a
Brake
light
switch
-F-
14.5 V
switch -F- to fuse S13.
max.
1.5
394
12 + 38
14 + 38
9 + 12
Jumper l
Test conditions
additional works
Ignition off
Detach multi-pin
connector -T47aConnect -V.A.G 1598 Awith adapter -V.A.G
1598/36Test wiring for open
circuit
Test covers
additional
works
33 + 34 Resistance of the
Ignition
l
front right speed
off
sensor -G45-
k
sensor.
45 + 46 Resistance of the
Ignition
l
front left speed
off
sensor -G47-
k
sensor.
locations
If the lines are not found to be faulty:
Replace speed sensor -G47 Chapter.
Test covers
additional
works
42 + 4 Resistance of the
Ignition
l
rear right speed
off
sensor -G44-
k
sensor.
37 + 36 Resistance of the
Ignition
l
rear left speed
off
sensor -G46-
k
sensor.
Test -V.A.G
step 1598 Abushes
additional
works
Specified
value
of the front
voltage min. wheel speed sensor and the
l Ignition off
right speed
65 mV
pulse rotor.
sensor -G45Turn front right
wheel by
approx. 1 turn
Check wheel speed sensor -G45per sec.
to ensure it is correctly
Alternating
Check the installation of the
Alternating
Check the installation of the
Alternating
Check the installation of the
Specified value
The warning
light -K47lights up for
approx. 2
seconds and
goes out
Ignition off
The multi-pin
connector is inserted
l
on the control unit
-J104- and locked
Switch on ignition
Functional test: Hand brake/brake fluid level warning light -K14/33Test -V.A.G
ste 1598 Ap bushes
15
Test covers
Specified value
l Test conditions
additional
works
Function of the
Brake fluid level
l
hand brake/brake is O.K.
fluid level
l Ignition off
warning light
-K14/33Multi-pin
connector
inserted on
l
control unit
-J104- and
locked
The warning
light -K14/33lights up for
approx. 2
seconds and
goes out
Switch on
ignition
Functional test: ESP warning light -K155Test -V.A.G Test covers l Test conditions
ste 1598 A additional works
398
bushes
16
ignition
to earth. Current flow
diagrams, Electrical fault
finding and Fitting locations
Check dash panel insert,
fault in the dash panel
insert.
Check ESP button -E256-.
Test voltage supply relay for
warning light -K155-.
Functional test: Warning light -K155- for the function of the ESP button -E256- in test step 17;
voltage supply (20 V=) in test step 17a
Test -V.A.G Test covers l Test conditions
ste 1598 A additional works
p bushes
17
Specified value
The warning
light -K155lights up for
approx. 2
seconds and
goes out
Multi-pin
connector
l inserted on
control unit -J104and locked
Switch on
ignition
399
17a
Warning light
-K155- comes
on
Operate ESP
button
Warning light
Operate ESP
button once again -K155- goes out
16 + Function of
Switch off
13 the
ignition
TCS/ESP
Disconnect the
button
multi-pin
-E256
connector from
the control unit
-J104-
Connect -V.A.G
1598 A- with
adapter -V.A.G
1598/36
Switch on
ignition
3,5-5,0 V
8,0-14,5 V
Test covers
l Test conditions
additional works
steering angle
sender -G85-
steering angle
sender at the plug
connection -T6w
18a
11 + Cables for
15 steering angle
sender -G85-
10.014.5V
Measuring range
200 set
Connect -V.A.G 1598
A- with adapter
-V.A.G 1598/36Check the following
line connections for
an open circuit:
Wiring of contact
-T6w/3- (steering
Wiring of contact
-T6w/1- to earth
Measuring range 20
MQ set
401
Test covers
Test conditions
additional works
Cables for
l
Ignition off
lateral
Measuring range 200
acceleration
l
set
sender -G200Disconnect the multi pin connector -T47afrom the control unit
-J104
Wiring of contact
-T3n/1- (lateral
acceleration sender)
with contact -T47a/6(control unit)
Wiring of contact
-T3n/2- (lateral
acceleration sender)
with contact -T47a/24(control unit)
Wiring of contact
402
max.
1.5
-T3n/3- (lateral
acceleration sender)
with contact -T47a/26(control unit)
l
Measuring range 20 M
set
Check cables for shortcircuit to positive or to
earth
Test covers
Cables for
lateral
acceleration
sender -G200-
Test conditions
additional works
Ignition off
Measuring range
200 set
Wiring of contact
-T3m/1- (yaw rate
sender) with contact
-T47a/6- (control unit)
Wiring of contact
-T3m/2- (yaw rate
sender) with contact
-T47a/24- (control
403
unit)
Wiring of contact
-T3m/3- (yaw rate
Cables for
brake
pressure
sender -1-G201-
Test conditions
additional works
Ignition off
Wiring of contact
-T30/1- (brake pressure
sender) with contact
-T47a/19- (control unit)
Wiring of contact
-T30/2- (brake pressure
404
1.5
Current flow diagrams,
Electrical fault finding and
Fitting locations
Measuring range 20 M
set
Check cables for shortcircuit to positive or to
earth
Test covers
Test conditions
additional works
Cables for
l
Ignition off
longitudinal
acceleration l Measuring range 200 set
sender -G251- Disconnect the electrical plug
connection from the
longitudinal acceleration
sender -G251
max.
Check the cables between
Test the wiring
the multi-pin connector of the 1.5
according to the current
longitudinal acceleration
flow diagram binder
sender -G251- and the multiCurrent Flow Diagrams,
pin connector of the control
Electrical Fault Finding
unit -J104- for open circuit
and Fitting Locations
l Measuring range 20 M set
bushes
11 + 15
23
Specifie
d value
Test conditions
additional works
Data l
Ignition off
BUS
cables l Measuring range 200 set
Disconnect the multi-pin
plug connections from the
control units connected to
the data BUS
Connect -V.A.G 1598 A with adapter -V.A.G
1598/33 Test wiring for open circuit
max.
1.5
1)
Test covers
Test conditions
additional works
Specifie
d value
1)
Contact assignment of the plug connection for the voltage supply and the self-diagnosis
with the vehicle system tester -V.A.G 1552- Chapter.
Test covers
l Test conditions
additional works
max.
1.5
1598/33Test wiring
between contact
-T16a/7- and
contact -T47a/39l
Measuring range
20 M set
Check cables for
short-circuit to
positive or to earth
408
Piston jig -MP 9-403Brake pedal load, e.g. -V.A.G 1238/BBrake filling and bleeding device, e.g. -VAS 5234Bleeding bottle (commercially available)
Brake fluid Chapter
Solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
Note
After replacing the brake pads, depress brake pedal firmly several times when the vehicle
t is stationary to ensure the brake pads are properly seated in their normal operating
position.
t
Before removing a brake caliper or separating a brake hose from the brake caliper, the
brake pedal must be locked; e.g. with brake pedal load -V.A.G 1238/B-.
Use a bleeding bottle, that only comes into contact with the brake fluid, to drain brake fluid
t from the brake fluid reservoir. Brake fluid is toxic and must never be sucked into your
mouth via a hose!
t
12-
4 Nm
Brake disc
Thickness: 22 mm
Wear limit: 19 mm
t
t
3t
Brake pads
with wear indicator - with a corresponding wear (limit: 2 to 3 mm) the warning light in the
dash panel insert lights up
t
t
t 05.98 : do not interchange the inside and outside brake pads Chapter
4-
Brake caliper
removing:
Installing:
repairing Chapter
5t
Guide bolt, 30 Nm
removing and installing Chapter
67t
Cap
Brake hose with banjo union and hollow screw
cannot be disassembled, must be fully replaced
Tightening torque: 35 Nm
8-
Wheel-bearing housing
910 t
8 Nm
ABS wheel speed sensor
clean the inner surface of the hole before inserting the wheel speed sensor and coat with a
solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
11 -
Cover plate
12 13 t
t
14 -
10 Nm
Wheel bearing
replace after each removal
pressing in and pressing out Chapter
Circlip
411
15 t
16 t
Piston jig -MP 9-403Brake filling and bleeding device, e.g. -VAS 5234Bleeding bottle (commercially available)
Brake fluid Chapter
Remove wheels.
Note
t
t
When removing mark the brake pads you intend to keep using. Install in the same location,
as otherwise this may cause uneven braking!
Do not unscrew the brake hose when replacing the brake pad.
Disconnect the plug connection for the brake pad wear indicator (where the vehicle is
fitted with this).
412
Install
Note
413
414
Piston jig -MP 9-403Brake pedal load, e.g. -V.A.G 1238/BBrake filling and bleeding device, e.g. -VAS 5234Bleeding bottle (commercially available)
Brake fluid Chapter
Solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
Note
After replacing the brake pads, depress brake pedal firmly several times when the vehicle
t is stationary to ensure the brake pads are properly seated in their normal operating
position.
t
Before removing a brake caliper or separating a brake hose from the brake caliper, the
brake pedal must be locked; e.g. with brake pedal load -V.A.G 1238/B-.
Use a bleeding bottle, that only comes into contact with the brake fluid, to drain brake fluid
t from the brake fluid reservoir. Brake fluid is toxic and must never be sucked into your
mouth via a hose!
t
415
12t
4 Nm
Brake disc
the max. axial run-out is not marked
t released combination of a brake disc without marking and a wheel hub with marking
t
t
t
t
t
3-
t with a marking approx. 5 mm wide for marking the maximum wheel run-out
t released combination of a brake disc with marking and a wheel hub without marking
t
t
t
Do not use force to separate the brake discs from the wheel hub, if necessary use rust
solvent, as you could otherwise damage the brake discs.
4t
Brake pads
with wear indicator - with a corresponding wear (limit: 2 to 3 mm) the warning light in the
dash panel insert lights up
5t
Retaining spring
insert in both bores of the brake caliper housing.
6-
Brake carrier
t must be assembled with sufficient grease on the guide bolt, supplied as a spare part
t
if there is any damage to the protective caps or guide bolts fit a repair set (use the enclosed
grease packing to lubricate the guide bolts)
7t
Brake caliper
removing:
Remove brake pads -Pos. 4
Insert brake pedal load.
Unscrew brake hose -Pos. 10- from brake caliper.
Installing:
t
t
8-
9-
Cap
10 t
Tightening torque: 35 Nm
11 t
124 Nm
Clean ribbing on the underside
12 -
Wheel-bearing housing
13 14 t
8 Nm
ABS wheel speed sensor
clean the inner surface of the hole before inserting the wheel speed sensor and coat with a
solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste).
15 -
Cover plate
16 17 t
10 Nm
Wheel bearing
replace after each removal
18 19 t
Circlip
Wheel hub with pulse rotor
In combination with the wheel hub without marking of the min. axial run-out and the brake
t disc without marking of the min. axial run-out or permissible vice versa, the reduction of the
overall axial run-out of the brake FN 3 is then not effective.
t
t
t
Piston jig -MP 9-403Brake filling and bleeding device, e.g. -VAS 5234418
t
t
Remove wheels.
Note
t
t
When removing mark the brake pads you intend to keep using. Install in the same location,
as otherwise this may cause uneven braking!
Do not unscrew the brake hose when replacing the brake pad.
Note
419
420
421
Tightening torque: 30 Nm
422
Brake judder, brake pulsations or steering wheel torsional vibrations can occur with the
t brake FN 3. This is caused by a too great overall axial run-out in the system brake disc wheel hub.
t
In order to reduce the overall axial run-out, the maximum and minimum axial run-out of
the brake disc and the wheel hub is marked with an ink-jet marking.
When handling a fault due to a too great overall axle run-out, the wheel hubs and the
t brake discs which are not marked must be replaced with marked parts. Assignment
Electronic Catalogue of Original Parts
t
If used brake discs with a marking and a 5-hole fixing for wheel hubs are reinstalled, the
position of the brake disc to the wheel hub must be marked before removal.
The combination of marked brake disc/unmarked wheel hub or unmarked brake disc and
marked brake disc is allowed.
The combination of the left vehicle side components without marking and the right vehicle
side components with marking or vice versa is also allowed.
Pay attention that the reduction of the overall run-out on the brake FN 3 is not effective for
the stated combinations.
t
t
Removing
Remove wheel.
Note
Remove the brake carrier with the brake caliper and secure with wire in such a way that
the weight of the brake caliper does not burden or damage the brake hose.
Remove the brake disc/wheel hub connecting screw.
When handling a fault due to a too great overall run-out of the axle
Install
423
When handling a fault due to a too great overall run-out of the axle
Install a new wheel hub -1- with an ink-jet
marking approx. 3 mm wide for marking
the minimum axial run-out -arrow A- in
the wheel bearing housing Chapter.
Install a new brake disc -2- on the wheel
hub with an ink-jet marking approx. 5
mm wide for marking the maximum axial
run-out -arrow B-.
Fitting position:
Install the brake disc on the wheel hub in
such a way that the marking of the
minimum axial run-out (wheel hub) and the
maximum axial run-out (brake disc) are
located opposite each other.
Vehicles without a fault
After changing the brake disc (old wheel
hub/new brake disc), a minimisation of
t
the axial run-out is not possible on used
vehicles.
t
Tightening torques:
Brake disc to wheel hub
4 Nm
124 Nm
Wheel bolt
120 Nm
424
Check if the pistons can be slightly pressed into the brake cylinder.
t
t
After replacing the wheel-brake cylinder, brake carrier and brake shoe, forcefully apply the
brake pedal once to ensure the brake shoes go into their normal operating position.
Use a bleeding bottle, that only comes into contact with the brake fluid, to drain brake fluid
t from the brake fluid reservoir. Brake fluid is toxic and must never be sucked into your
mouth through a hose.
t
Use the brake pedal load, e.g. -V.A.G 1238/B-, before removing a brake cylinder, a brake
carrier or before separating a brake pipe from the wheel-brake cylinder.
425
12t
4 Nm
Brake drum
Brake drum diameter 230 mm
clean carefully, and check for wear, damage, dimensional accuracy and perfect brake
surface
Check noncircularity by means of a special tool -MP 5-407- and the dial gauge (measuring
range 0 - 10 mm).
Permissible noncircularity 0.03 mm. If the measured value is greater than 0.03 mm, the
brake drum must be replaced BookletOctavia.
3-
Cap
inserting Fig.
4-
5-
6-
7t
Self-locking screw, 50 Nm + 60
replace after each removal
8t
Installing:
repairing Chapter.
910 -
Axle body
Axle stud
11 12 t
t
8 Nm
ABS wheel speed sensor
only on vehicles with ABS
clean the inner surface of the hole before inserting the wheel speed sensor and coat with a
solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
427
Resetting brake
428
1t
Spring cap
to remove push against pressure spring and turn 90
2-
Pressure spring
3-
Locating spring
4-
Pressure rod
t Coat the points of contact with solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
5t
Wedge
when removing and installing the brake drum push up through a hole for wheel screw
Chapter
6-
Wheel-brake cylinder
removing:
7-
8 Nm
8-
Tensioning sleeve
9-
Brake carrier
10 t
11 t
12 13 t
Tension spring
Bottom retractor spring
Coat the contact points with solid lubricant paste -G 000 650-
14 15 t
Brake shoe
t
t
Cap
430
Removing
Remove wheels.
Remove the brake drum Chapter.
Remove spring cap with pressure springs.
431
Install
432
1-
Handbrake cable
434
435
t
t
After replacing the brake pads, depress brake pedal firmly several times when the vehicle
t is stationary to ensure the brake pads are properly seated in their normal operating
position.
Use a bleeding bottle, that only comes into contact with the brake fluid, to drain brake fluid
t from the brake fluid reservoir. Brake fluid is toxic and must never be sucked into your
mouth via a hose!
t
Before removing a brake caliper or separating a brake hose from the brake caliper, the
brake pedal must be locked; e.g. with brake pedal load -V.A.G 1238/B-.
436
1-
4 Nm
2-
Diameter 256 mm
Thickness 22 mm
Wear limit 20 mm
t
3-
Diameter 232 mm
Thickness 9 mm
Wear limit 7 mm
4-
Cap
inserting Chapter
5-
6-
7-
30 Nm + 90
8-
Cover plate
9-
Axle stud
10 -
Hand-brake cable
11 -
Axle body
12 -
clean the inner surface of the hole before inserting the wheel speed sensor and coat with a
solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
13 -
8 Nm
14 -
30 Nm + 30
15 -
t must be assembled with sufficient grease on the guide bolt, supplied as a spare part
t
t
fit a repair set if there is any damage to the protective caps or guide bolts; (use the
enclosed grease packing to lubricate the guide bolts)
Observe the instructions for changing the pad Chapter
16 -
do not unscrew the brake line when replacing the brake pad
17 t
always replace
18 t
Self-locking screw, 35 Nm
Brake caliper
do not unscrew the brake line when replacing the brake pad
removing
Installing:
t
t
repairing Chapter
Observe the instructions for changing the pad Chapter
t One must first adjust the hand-brake cable after undertaking repair or replacement work
The foot brake must not be applied beforehand!
t
19 -
Brake pads
t
t
20 t
t
t
t
t
Assembly device -T10165/1Brake filling and bleeding device, e.g. -VAS 5234Brake fluid Chapter
439
Note
t
t
When removing mark the brake pads you intend to keep using. Install in the same location,
as otherwise this may cause uneven braking!
Do not unscrew the brake hose when replacing the brake pad.
Removing
Remove wheels.
Unhook the handbrake cable from the brake caliper Chapter.
1-
Handbrake cable
442
443
Raise vehicle.
Remove wheel.
Install
Installation is carried out in the reverse
order.
Note
444
445
Install
Installation is carried out in the reverse
order.
Note
446
1-
Handbrake lever
t before the removal, remove the centre console Body Work; Rep. gr.68.
2t
Door handle
pull it out towards the front, first of all press the catch peg below the door handle towards
the bottom using a small screwdriver
3t
4t
56-
7-
Compensating clamp
8-
t
t
9-
Handbrake cable
different versions for the rear drum brake and disc brake Electronic Catalogue of Original
Parts.
10 -
t
t
clipped
replace if defective
448
t
t
After replacing the brake pads, depress brake pedal firmly several times when the vehicle
t is stationary to ensure the brake pads are properly seated in their normal operating
position.
Use a bleeding bottle, that only comes into contact with the brake fluid, to drain brake fluid
t from the brake fluid reservoir. Brake fluid is toxic and must never be sucked into your
mouth via a hose!
t
Before removing a brake caliper or separating a brake hose from the brake caliper, the
brake pedal must be locked; e.g. with brake pedal load -V.A.G 1238/B-.
449
12-
80 Nm
Brake carrier with guide bolts and protective caps
t must be assembled with sufficient grease on the guide bolt, supplied as a spare part
t
fit a repair set if there is any damage to the protective caps or guide bolts; (use the
enclosed grease packing to lubricate the guide bolts)
3-
Self-locking screw, 35 Nm
always replace
4-
t
5t
t
do not unscrew the brake line when replacing the brake pad
Brake caliper
do not unscrew the brake line when replacing the brake pad
removing:
Remove brake pads -Pos. 6
Insert brake pedal load.
450
Installing:
repairing Chapter
t
t
6-
Brake pads
t
t
7-
t
t
8-
Cover plate
910 t
t
10 Nm
Self-locking twelve-point nut
replace after each removal
tighten Chapter
11 12 -
4 Nm
Brake disc, internally ventilated
Diameter 256 mm
Thickness 22 mm
Wear limit 20 mm
13 -
Brake disc
Diameter 232 mm
Thickness 9 mm
Wear limit 7 mm
14 t
15 t
Circlip
replace after each removal
16 t
Wheel bearing
replace after each removal
17 18 -
Trailing arm
Hand-brake cable
19 t
clean the inner surface of the hole before inserting the wheel speed sensor and coat with a
solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
20 21 t
8 Nm
Drive shaft
removing and installing Chapter
Resetting tool -T10165Assembly device -T10165/1Brake filling and bleeding device, e.g. -VAS 5234Bleeding bottle (commercially available)
Brake fluid Chapter
452
Note
t
t
When removing mark the brake pads you intend to keep using. Install in the same location,
as otherwise this may cause uneven braking.
Do not unscrew the brake hose when replacing the brake pad.
Removing
Raise vehicle.
Remove wheels.
453
454
455
t
t
456
1-
Handbrake cable
457
458
Install
Installation is carried out in the reverse
order.
Note
459
The travel of the brake pedal must not be shortened by additional floor coverings.
Note
t Grease bearing and contact surfaces with grease -MoS2- (molykote grease).
t
When using a pedal with mechanical accelerator control, separate the accelerator control
t from the accelerator pedal before removing the mounting bracket Engine,
Mechanics; Rep. gr.20
1t
2t
Bearing bracket
removing and installing Chapter
Self-locking nut, 28 Nm
replace
4 pieces for securing the mounting bracket to the brake servo unit
3t
before assembling the brake light switch, clip the brake pedal to the pressure rod of the
brake servo unit Chapter
4t
Accelerator pedal
removing and installing: Engine, Mechanics; Rep. gr.20
5-
Self-locking nut, 25 Nm
6t
t
Brake pedal
separate from the brake servo unit Chapter
removing and installing Chapter
7-
Cap
8-
Screw
9-
Bushing
10 -
Bearing bolt
The travel of the brake pedal must not be shortened by additional floor coverings.
Note
t Grease bearing and contact surfaces with grease -MoS2- (molykote grease).
t
When using a pedal with mechanical accelerator control, separate the accelerator control
t from the accelerator pedal before removing the mounting bracket Engine,
Mechanics; Rep. gr.20.
461
1t
2t
Bearing bracket
removing and installing Chapter
Self-locking nut, 28 Nm
replace
462
4 pieces for securing the mounting bracket to the brake servo unit
3t
before assembling the brake light switch, clip the brake pedal to the pressure rod of the
brake servo unit Chapter
45-
Screw
Brake pedal
Cap
Self-locking nut, 25 Nm
Bushing
Bearing bolt
10 11 -
Strut
Self-locking nut, 10 Nm
Separating the brake pedal from the brake servo unit and clipping
Special tools and workshop equipment required
t
463
464
1-
Brake pedal
2-
Pressure rod
3-
Retaining lugs
Tightening torques:
Connecting plate between clutch pedal and brake pedal
465
20 Nm
Removing
466
RHD vehicles
Remove the nut for the strut attached to
the mounting bracket and divert the
strut.
Continued for all vehicles
Install
Note
Tightening torques:
Brake pedal to bracket
t
28 Nm
468
20 Nm
1t
t
t The brake assistance cannot be repaired, replace the brake servo unit completely when
469
check Chapter
t on petrol engines the required negative pressure is drawn from the induction pipe
t vehicles using a diesel engine are fitted with a vacuum pump for generating a low pressure
t
Functional test
It must be possible to blow through the valve in the -direction of the arrow-.
2t
Screw cap
with integrated brake fluid level warning contact -F34-
3-
4t
Plugs
moisten with brake fluid and press in expansion reservoir
5-
Retaining pin
6t
two brake pressure senders (-G201- and -G214-) are additionally installed on vehicles with
ABS/EDL/ESP
7t
Self-locking nut 20 Nm
only for vehicles with 74 kW, 92 kW and 110 kW engine
8t
Heat shield
only for vehicles with 74 kW, 92 kW and 110 kW engine
9t
10 -
Self-locking nut 20 Nm
replace
Sealing ring
470
replace
11 -
Plugs
12 -
Vacuum hose
13 -
Gasket
14 t
Self-locking nut, 28 Nm
replace
Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles without ABS or
with ABS, ABS/EDL Mark 20 - RHD vehicles
Note
The complete master brake cylinder and brake servo unit can be replaced independently of
one another.
471
1t
t
t
t
t
t
check Chapter
t on petrol engines the required negative pressure is drawn from the induction pipe
t vehicles using a diesel engine are fitted with a vacuum pump for generating a low pressure
t
2t
Screw cap
with integrated brake fluid level warning contact -F34-
3-
4-
Plugs
5-
Plugs
t moisten with brake fluid and press expansion reservoir into the sealing surfaces
6-
Self-locking nut, 20 Nm
7-
8-
9t
Sealing ring
replace
10 t
t
Gasket
for brake servo unit
between brake servo unit and bulkhead
473
replace
11 -
Self-locking nut, 28 Nm
replace
Before disconnecting the battery determine the code of the radio sets fitted with anti-theft
coding.
After reconnecting the battery, a few additional operations must be carried out Electrical
System; Rep. gr.27
Removing
The following 2 work steps do not apply to the 1.6 ltr./55 kW engine:
474
Disconnect plug -1- from brake fluid level warning contact -F34-.
Using an extraction bottle extract as much brake fluid as possible from the brake fluid
reservoir.
Clamp off the running-on line of the clutch master cylinder -2- with hose clamp -MP 7-602-.
Disconnect the running-on line of the clutch master cylinder -2- from the brake fluid
reservoir -3- and tie up.
Unscrew the brake lines from the tandem master brake cylinder, close the brake lines with
the screw plugs from the repair kit SP no. -1 HO 698 311 A-.
Unscrew the tandem master brake cylinder from the brake servo unit.
Install
Installation is carried out in the reverse order.
Replace the gasket ring between the master brake cylinder and the brake servo unit.
When installing the master brake cylinder with the brake servo unit pay attention to the
correct positioning of the pressure rod in the master brake cylinder.
Only fill up with new brake fluid after installing Chapter.
Connect battery Electrical System; Rep. gr.27.
Bleeding Brake System Chapter.
Bleed clutch system (manual gearbox) Manual Gearbox; Rep. gr.30.
Repairing the clutch control BookletOctavia.
Initiate the basic setting on vehicles with EDL Chapter.
Interrogate the fault memory Chapter.
Erasing fault memory Chapter.
475
Before disconnecting the battery determine the code of the radio sets fitted with anti-theft
coding.
Removing
Unscrew the brake lines from the tandem master brake cylinder -2- and -3-.
Shut-off brake lines with screw plugs from the repair kit SP No. -1 HO 698 311 A-.
Unscrew the tandem master brake cylinder from the brake servo unit.
Install
Installation is carried out in the reverse order.
Replace the gasket ring between the master brake cylinder and the brake servo unit.
When installing the master brake cylinder with the brake servo unit pay attention to the
correct positioning of the pressure rod in the master brake cylinder.
Only fill up with new brake fluid after installing Chapter.
Connect battery Electrical System; Rep. gr.27.
Note
After reconnecting the battery, a few additional operations must be carried out Electrical
System; Rep. gr.27
477
With the engine off press down brake pedal repeatedly with force (this reduces the pressure
already present in the device).
Now hold the brake pedal in brake position using a medium foot pressure and start the
engine.
If the brake servo unit operates perfectly the brake pedal must yield noticeably under your
foot (servo boost takes effect).
With the engine running (full vacuum support must be guaranteed) forcefully apply the
brake pedal. While doing so, a "click" must be audible (the brake assistance is activated).
If no "click" is audible, then the brake assistance is defective and the brake servo unit must
be replaced completely.
When subsequently releasing the brake pedal, a considerably reduced force is exerted onto
the foot from the brake pedal when braking.
t
t
t
t
478
Note
Before disconnecting the battery determine the code of the radio sets fitted with anti-theft
coding.
Removing
479
Re-set clock.
initialise power windows on vehicles
fitted with power windows
BookletOctavia.
480
Hose clamp -MP 7-602Brake pedal load, e.g. -V.A.G 1238 BBrake filling and bleeding device, e.g. -VAS 5234Vehicle system tester -V.A.G 1552Release tool -T10159AExtraction bottle (commercially available)
Repair set SP.-no. -1H0 698 311 ABrake fluid Chapter
Note
Before disconnecting the battery determine the code of the radio sets fitted with anti-theft
coding.
Removing
Remove induction pipe with exhaust gas recirculation valve and intake manifold Engine,
Mechanics; Rep. gr.26.
Install
482
Set clock.
Initialise power windows on vehicles
fitted with power windows
BookletOctavia.
Bleeding Brake System Chapter.
483
Removing and installing the vacuum pump for the brake servo unit
Vehicles with diesel engine
Engine, Mechanics; Rep. gr.15
484
The brake calipers must absolutely be pre-bled before installing them in the vehicle
t (without brake pads) in case of a repair or when replacing them with new brake calipers
Chapter.
t Thinly coat brake cylinder, piston and gasket ring with brake fluid or assembly paste.
12t
3-
Dust cap
Vent valve, 10 Nm
thinly coat thread with brake fluid or assembly paste before screwing in
Bushing
485
4-
Guide bolt, 30 Nm
5-
Caps
insert in bushing
6-
Brake caliper
7t
Sealing ring
removing and installing Chapter
8t
t
Piston
removing and installing Chapter
first thinly coat piston with assembly paste or brake fluid
9t
Protective cap
do not damage when inserting the piston
Removing
486
487
488
The brake calipers must absolutely be pre-bled before installing them in the vehicle
t (without brake pads) in case of a repair or when replacing them with new brake calipers
Chapter.
t Thinly coat brake cylinder, piston and gasket ring with brake fluid or assembly paste.
1t
23-
Cap
insert in bushing
Guide bolt, 28 Nm
Bushing
489
4-
Dust cap
5t
Vent valve, 10 Nm
thinly coat thread with brake fluid or assembly paste before screwing in
6-
Brake caliper
7-
Brake carrier
8t
9-
Sealing ring
10 t
t
Piston
removing and installing Chapter
Piston diameter: 54 mm
11 -
Protective cap
t insert with the inner sealing lip into the groove of the brake caliper Chapter
Removing
490
491
492
t
t
t
The brake calipers must absolutely be pre-filled with brake fluid before installing them in
t the vehicle (without brake pads) in case of a repair or when replacing them with new brake
calipers Chapter.
t Thinly coat brake cylinder, piston and gasket ring with brake fluid or assembly paste.
1t
t
Self-locking screw, 35 Nm
replace
counterhold on the guide bolt when releasing and tightening
493
2-
Vent valve, 10 Nm
t thinly coat thread with brake fluid or assembly paste before screwing in -G 052 150 A23-
Dust cap
4-
Guide bolt
5-
Protective cap
6-
t must be assembled with sufficient grease on the guide bolt, supplied as a spare part
t
if there is any damage to the protective caps or guide bolts fit a repair set (use the enclosed
grease packing to lubricate the guide bolts)
7-
Protective cap
t insert with the inner sealing lip into the groove of the brake caliper housing Chapter
8-
t thinly coat piston with brake fluid or assembly paste before installing -G 052 150 A29-
Sealing ring
10 -
t replace brake caliper housing if the lever for the handbrake cable is not sealed
t
t
t
t
Removing:
494
Installing:
Note
The brake caliper must be positioned vertically for pre-bleeding.
496
1t
2t
34t
567-
Brake-power regulator
testing and adjusting Chapter
Brake line with pipe screw
Tightening torque of the pipe screw 14 Nm
Oval-head countersunk screw, 21 Nm
Self-locking nut, 21 Nm
replace after each removal
Tension spring
16 Nm
Socket nut
8t
Screw
replace after each removal
t Brake-power regulator or brake system tester, e. g. -V.A.G 1310- or -V.A.G 1310 AThe brake-power regulator is secured to a
bracket assigned to the mount for rear axle
and is controlled by the rear axle
movement via a spring.
Functional test
Forcefully apply the brake pedal and
release quickly (vehicle is standing on its
wheels). While doing so the lever of the
brake-power regulator must move.
Pressure test and adjustment
Note
498
Compare measured
pressure values to
the specified
adjusting values
Chapter.
If necessary adjust
brake-power
regulator Chapter.
499
bar
MPa
bar
MPa
Front axle
70
Front axle
100
10
Rear axle
Rear axle
41 ... 47
Rear axle
54 ... 60
Adjust without load on the brake pedal, observe the following sequence:
Bleed brake system, vehicles with or without ABS or ABS/EDL Mark 20 and Mark 60
Special tools and workshop equipment required
t
t
t
Brake filling and bleeding device, e.g. -VAS 5234Brake pedal load, e.g. -V.A.G 1238/BVehicle system tester -V.A.G 1552- (only for vehicles with ABS/EDL)
Note
Only use new brake fluid complying with the standard Chapter.
t If the system is opened, avoid working with compressed air and avoid moving the vehicle.
500
Bleeding the brake system is described using the brake filling and bleeding device, e.g.
-VAS 5234-.
If one chamber of the brake fluid reservoir has run completely dry, e.g. leakage in the brake
system, bleeding must be carried out using the brake filling and bleeding device, e.g. -VAS
5234-. Then the hydraulic unit is tested with the vehicle system tester -V.A.G 1552- in the
function "basic setting" or with the vehicle diagnosis, measurement and information system
-VAS 505x-.
Note
Brake fluid is hygroscopic, i.e. it retains humidity from the ambient air, and must therefore
always be stored in airtight containers.
Brake fluid must never come into contact with fluids containing mineral oils (oil, petrol,
cleaning agent). Mineral oils damage the plugs and boots of the brake system.
t Because of its caustic effect brake fluid must not come into contact with paint.
t
Connect up the brake filling and bleeding device e.g. -VAS 5234- but do not yet switch it
on.
Connect up the brake filling and bleeding device e.g. -VAS 5234- but do not yet switch it
on.
Insert brake pedal load.
If one chamber of the brake fluid reservoir has run completely dry (e.g. leakage in the brake
system) first of all a pre-bleeding of the brake system must be performed.
501
502
Bleeding brake system with brake filling and bleeding device for vehicles with Mark 20
Special tools and workshop equipment required
t
Vehicle system tester -V.A.G 1552- (only for vehicles with ABS/EDL)
Opening the bleeder screws on the hydraulic unit is not allowed on vehicles with ABS,
ABS/EDL!
Connect up the brake filling and bleeding device, e.g. -VAS 5234-, but do not yet switch it
on.
Remove dust caps from the bleeder screws of the brake calipers/wheel-brake cylinders.
Open the bleed valves in the prescribed sequence with the hose of the bleeding bottle
fitted, switch on the brake filling and bleeding device and bleed both the brake calipers and
the wheel-brake cylinders.
Bleeding sequence
1-
2-
3-
4-
After bleeding close the relevant bleeder screw and fit dust cap.
For vehicles with brake-power regulator move the rear wheel-brake lever of the regulator
during bleeding.
Change brake fluid BookletOctavia
503
Bleeding the brake system without using the brake filling and bleeding device
Special tools and workshop equipment required
t
Opening the bleeder screws on the hydraulic unit is not allowed on vehicles with ABS,
ABS/EDL!
Note
While bleeding continuously check the brake fluid level in the brake fluid reservoir. If
necessary, top up brake fluid up to the MAX marking.
Open the bleeder screw with the hose of the bleeding bottle fitted.
Flush the brake fluid through the brake system by pumping the brake pedal.
2-
3-
4-
2-
3-
4-
For vehicles with brake-power regulator move the rear wheel-brake lever of the regulator
during bleeding.
Change brake fluid BookletOctavia
504
505
Bleeding brake system with brake filling and bleeding device for vehicles with ABS Mark 60
brake filling and bleeding device and bleed both the brake calipers and the wheel-brake cylinders.
Bleeding sequence
1Front left brake caliper
2Front right brake caliper
3Rear left brake caliper
4Rear right brake caliper
After bleeding the relevant valve, close the vent valve and fit on the dust cap.
After bleeding perform a test drive. While doing so perform at least one ABS adjustment!
Pre-bleed the brake system if one chamber of the brake fluid reservoir has run completely empty (e.g.
leakage in the brake system).
Bleeding sequence
1Bleed the front left and front right brake caliper simultaneously
2Bleed the rear left and rear right brake caliper simultaneously
Leave the bleeder screws on the plugged-on hose of the bleeder bottle open for as long as is takes until
Test condition
l
Test
506
Connect the
pressure gauge of
Test duration 45
seconds.
Separate the
pressure gauge of
the tester -V.A.G
1310- or -V.A.G 1310
A- from the brake
caliper.
Thinly coat the
thread of the vent
valve with brake
fluid or assembly
paste -G052 150
A2-.
Tightening torque: 10
507
Nm
Bleeding Brake
System
Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles with
ABS/EDL/ESP Mark 20
Note
The complete master brake cylinder and brake servo unit can be replaced independently of
one another.
1t
t on petrol engines the required negative pressure is drawn from the induction pipe
t vehicles using a diesel engine are fitted with a vacuum pump for generating a low pressure
t
Functional test
It must be possible to blow through the valve in the -direction of the arrow-.
2-
Self-locking nut 28 Nm
replace
3-
Gasket
4t
Bellows
pay attention to correct position, risk of suction noises
5-
Holder
6t
Screw cap
with integrated brake fluid level warning contact -F34-
7-
8-
Sealing ring
replace
9-
Retaining bracket
10 t
Plugs
11 -
Retaining pin
509
12 t
13 -
Self-locking nut 20 Nm
replace
14 t
Heat shield
15 t
16 17 t
Wiring loom
Brake pressure sender -2--G214in the push rod piston circuit
18 t
Connector
19 -
Plugs
20 t
t
Vacuum hose
with non-return valve
insert in brake servo unit.
Removing and installing brake pressure sender -1--G201- and brake pressure sender -2-G214-
Note
t Before disconnecting the battery determine the code of radio sets fitted with anti-theft
510
coding.
t
re-set clock
Disconnect battery.
511
2-
3-
Install
Installation is carried out in the reverse
order.
Tightening torques:
Brake pressure sender -1-
25 Nm
25 Nm
Note
Before disconnecting the battery determine the code of radio sets fitted with anti-theft
coding.
set clock,
Disconnect battery.
34-
513
Install
Installation is carried out in the reverse
order.
Replace the gasket ring between the
master brake cylinder and the brake
servo unit.
When installing the master brake cylinder
with the brake servo unit pay attention to
the correct positioning of the pressure
rod in the master brake cylinder.
Tightening torque:
Master brake cylinder to brake servo unit
20 Nm
Before disconnecting the battery determine the code of the radio sets fitted with anti-theft
coding.
Removing
515
Install
Installation is carried out in the reverse
order.
Replace the gasket ring between the
master brake cylinder and the brake
servo unit.
When installing the master brake cylinder
with the brake servo unit pay attention to
the correct positioning of the pressure
rod in the master brake cylinder.
516
Hose clamp -MP 7-602Brake pedal load, e.g. -V.A.G 1238 B- or -V.A.G 1869/2Vehicle system tester -V.A.G 1552Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3CRelease tool -T 10159 AExtraction bottle (commercially available)
Repair kit -1 HO 698 311 ABrake fluid Chapter
Note
t
t
Before disconnecting the battery determine the code of the radio sets fitted with anti-theft
coding.
After connecting the battery check the vehicle equipment:
on vehicles with radio encoding, carry out the coding,
set clock,
Disconnect battery.
517
518
519
Tightening torque:
28 Nm
Hose clamp -MP 7-602Brake pedal load, e.g. -V.A.G 1238 BBrake filling and bleeding device, e.g. -VAS 5234Vehicle system tester -V.A.G 1552Release tool -T10159AExtraction bottle (commercially available)
Repair set SP.-no. -1H0 698 311 ABrake fluid Chapter
Note
Before disconnecting the battery determine the code of the radio sets fitted with anti-theft
520
coding.
Removing
Remove induction pipe with exhaust gas recirculation valve and intake manifold Engine,
Mechanics; Rep. gr.26.
Install
521
Set clock.
Initialise power windows on vehicles
fitted with power windows
BookletOctavia.
Bleeding Brake System Chapter.
522
Removing and installing the vacuum pump for the brake servo unit
Vehicles with diesel engine
Engine, Mechanics ; Rep. gr.15
Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles with
ABS/EDL/TCS/ESP Mark 60
Note
The complete master brake cylinder and brake servo unit can be replaced independently of
one another.
1t
t Left-hand drive vehicles with ABS/EDL/TCS/ESP Mark 60 up to and including model year
523
2001
- Brake servo unit with mechanical brake assistance
t Left-hand drive vehicles with ABS/EDL/TCS/ESP Mark 60 as of model year 2002
t
The brake assistance can only be recognized by the spare part number of the brake servo
unit
The brake assistance cannot be repaired, replace the brake servo unit completely when
handling a fault LHD vehicles Chapter, RHD vehicles Chapter
check Chapter
t on petrol engines the required negative pressure is drawn from the induction pipe
t vehicles using a diesel engine are fitted with a vacuum pump for generating a low pressure
t
the electric brake vacuum pump is additionally installed on vehicles with automatic gearbox
and in combination with EU4 -V192-
Functional test
2t
3t
It must be possible to blow through the valve in the -direction of the arrow-.
Against the direction of the arrow the valve must be closed.
Screw cap
with integrated brake fluid level warning contact -F34Brake fluid reservoir, left-hand drive
locked with lateral catches in the retaining pin
4t
5t
6t
7-
Plugs
moistened with brake fluid, press in expansion reservoir
Retaining pin
fit through the master brake cylinder
Master brake cylinder
cannot be repaired, replace completely in the event of faults
Retaining bracket
524
8-
Self-locking nut 20 Nm
always replace
9t
Heat shield
only for vehicles with 74 kW, 92 kW, 110 kW and 132 kW engine
10 t
11 t
Sealing ring
always replace
12 t
t
Plugs
Connection for vacuum hose
insert in brake servo unit.
13 t
t
t
14 -
Gasket
for brake servo unit
between brake servo unit and bulkhead
always replace
Self-locking nut 20 Nm
525
Removing and installing brake pressure sender -1--G201When using the hydraulic control unit Mark 60, the master brake cylinder has only one brake
pressure sender.
removing and installing Chapter
No provision is made for repairing the brake vacuum pump -V192-. The brake vacuum pump -V192- must
be replaced if a fault arises.
The fitting location of the brake vacuum pump -V192- can be found on the bottom left of the assembly
carrier
Removing
526
Remove bracket.
Unscrew the screws -3- for further disassembly
Tightening torques:
Nut -2- to bracket
Screws -3- to bracket
Screw -4- to bracket
Inner Torx screw for brake vacuum pump -V192- to bracket
20 Nm
8 Nm
20 Nm
8 Nm
Testing brake vacuum pump -V192During the start operation, the brake vacuum pump must start -V192- running briefly.
Work procedure
Interrogate the fault memory of the engine control unit Engine, Fuel Injection and Ignition
System; Rep. gr.01.
527
Steering
Steering column and steering wheel with airbag
Check the steering column for damage
completely.
New steering columns supplied as spare parts are secured for transport. This transport
security must be removed once the steering column has been installed.
The steering column is supplied as a spare part with ignition lock housing but without lock
cylinder and ignition starter switch.
t
t
t It can happen that on new steering columns, which are supplied as spare parts, the lock
528
cylinder and the ignition starter switch from the old steering column must be refitted or
must be obtained as a spare part and installed Electrical System; Rep. gr.94.
t
t
t
set clock,
Disconnect battery.
529
530
532
533
RHD vehicles
LHD vehicles
RHD vehicles
535
Install
Note
LHD vehicles
RHD vehicles
537
538
539
540
Removing and installing the ignition lock housing with the steering column mounted
541
Note
Before disconnecting the battery determine the code of radio sets fitted with anti-theft
coding.
re-set clock
Install
immobiliser.
543
If the front axle is damaged as a result of an accident certain steering components must be
replaced Chapter.
No provision is made for repairing on the power-steering gear. If there are any complaints
about the steering gear, replace it.
t
t
t
t
t
544
1t
Heat shield
centre with mounting bracket on the power-steering gear
2-
Nut, 23 Nm
3-
Bearing bracket
4-
23 Nm
5-
6-
20 Nm + 90
7-
Sealing sleeve
8t
t
Return-flow line
from the power-steering gear to the reservoir for central hydraulic oil
the distance to the power-steering gear must be 10 mm
9t
10 t
11 t
12 t
13 14 15 t
16 t
17 t
18 -
Gasket rings
replace after each removal
Hollow screw, 45 Nm
M16 x 1.5
Hollow screw, 38 Nm
M14 x 1.5
Pressure line (expansion hose)
from the vane pump to the power-steering gear
Counternut, 50 Nm
Steering-knuckle arm of the wheel-bearing housing
Self-locking nut, 50 Nm
replace after each removal
100 Nm + 90
replace after each removal
100 Nm + 90
replace after each removal
20 Nm + 90
545
19 -
Pendulum support
20 t
40 Nm + 90
replace after each removal
21 t
20 Nm + 90
replace after each removal
22 t
20 Nm + 90
replace after each removal
23 -
Assembly carrier
24 -
Retaining clip
25 -
Nut, 23 Nm
26 -
Fitting position:
t
27 t
t
Power-steering gear
adjust Chapter
removing and installing Chapter
t Hydraulic oil -TL 52 146-, -N 052 146 00- e.g. -PENTOSIN CHF 11 S (G 002 000)-
546
1t
t
2t
t
3t
t
4t
t
5-
t
t
t
Gearbox jack with adapter, e.g. -V.A.G 1383A- with -V.A.G 1359/2-
Plastic screw plugs for line connections on the power-assisted steering gear (commercially
available)
t Hydraulic oil -TL 52 146-, -N 052 146 00- e.g. -PENTOSIN CHF 11 S (G 002 000)Note
t
t
Apart from replacing the bellows and the track rods, no provision is made for further
repairs.
Absolute cleanliness is required when working on the power steering.
t Thoroughly clean the connection points and their surroundings before releasing.
t
t
t
t
t
Place removed parts on a clean surface and cover if the repair cannot be carried out
immediately.
Do not use fluffy cloths.
Remove spare parts from their wrapping immediately before fitting.
Use only genuine wrapped parts.
Do not use drained hydraulic oil again.
Disposal Chapter.
Removing
548
549
550
Screw down the hexagon nut -1sufficiently until the track rod extractor
cannot damage the thread.
551
Install
WARNING
553
554
Always replace the steering components -Pos. 1- up to -Pos. 9- after an accident or in the
event of damage to the front axle.
No provision is made for repairing on the power-steering gear. The cause of any problems
t which may arise is determined by the pressure test and tightness test. If there is a fault,
replace the power-steering gear.
t
Only use steering gear grease -AOF 063 000 04- in order to grease the gear rack (filling
capacity 23 ... 27 g).
556
1t
check Anchor
Counternut, 50 Nm
3-
replace
tensioning Anchor
4-
Bellows
inspect for wear (cuts, splits), inspect sealing surfaces and sealing lips for cleanliness or
damage
5t
t
t
6t
8-
Power-steering gear
t
t
t
t
9-
t
t
check Anchor
removing and installing Anchor
On a raised vehicle (wheels clear of the ground) inspect play by moving the track rods and
the wheels, specified value play: no play
Inspect attachment.
Inspect boots for damage and correct installation.
558
I - Left track rod end -LII - Right track rod end -Rt
559
the right and left side of the powersteering gear. If the dimension on the two
sides is not the same, distance -a- must
be corrected.
561
562
The track rods were adapted because of the modified track rod ends.
The track rods were shortened in comparison with the previous version.
Installed as of:
Vehicle identification number TMBZZZ1U2W2074066
Distinguishing feature of the previous track rod
Dimension -a- = 343,1 mm
Distinguishing feature of the modified track rod
Dimension -a- = 318,9 mm
WARNING
A mixed assembly of previous and modified track
rods is not permissible. In any case, both track
rods must be replaced. In addition, the modified
track rods must not be fitted with the previous
track rod ends.
The oils used in the power-steering gears do not contain any harmful substances. These oils may be
disposed of together with the drained engine and gearbox oil.
Dispose of used oils in compliance with the applicable environmental regulations.
Used oils (this concept refers to used engine and gear oils including ATF as well as mineral hydraulic
oils), suitable for preparation must never be mixed with brake fluid, antifreeze agent, artificial resin or
thinners, chemicals etc.
After "draining" the used parts must be allowed to drip adequately.
When disposing of used parts comply with the legal specifications as there are minor residual amounts of
hydraulic oil in the power-steering gears.
Note
Two mechanics are required for this adjustment. The adjustment must be done when the engine is not
running.
564
Check the hydraulic oil level of the power-assisted steering, top up if necessary
Special tools and workshop equipment required
t Hydraulic oil -TL52 146-, -N 052 146 00- e.g. -PENTOSIN CHF 11S(G002 000)Note
t Inspection service: oil level between MIN and MAX marking BookletOctavia
Hydraulic oil in a cold condition:
Do not start the engine and put the front wheels in a straight ahead position
Unscrew screw cap.
Wipe the oil dipstick with a clean cloth.
565
Only the oil level for a previously fully screwed in lid applies.
566
Do not let the engine run and raise the vehicle until the front wheels are fully off the
ground.
Place the catch pan for hydraulic oil underneath.
Open the hydraulic system on the suction side and return flow side and drain the
hydraulic oil.
Press out the residual hydraulic oil by turning the steering repeatedly from stop to stop.
t
t
t
hydraulic oil.
If metal swarf is found in the hydraulic oil and/or in the reservoir, the reservoir as well as
the suction and pressure lines must be cleaned very carefully and if necessary replaced.
Check the power steering system for tightness after assembly work and in the event of
hydraulic oil loss in the reservoir.
Start engine.
Turn the steering wheel in both directions up to the end stop and hold for a short while.
This will build up the highest possible pressure.
Check all line and hose connections for correct position and tightness.
In the event of leaks tighten the line or hose connections to the allowed tightening torques
or replace the seal or line.
Check hoses and lines for leaktightness. If there are leaks replace the relevant hose or
568
line.
Check vane pump for tightness. If there are leaks, replace the vane pump.
Check the hydraulic oil reservoir for tightness. If there are leaks, replace the reservoir.
Check the level of hydraulic oil, if necessary top up with oil Chapter.
Note
If there is a repeated loss of hydraulic oil from the reservoir and if the hoses and lines as well
as their connections, the vane pump and the reservoir have been thoroughly inspected
repeatedly, remove and inspect the power-assisted steering gear.
569
570
In order to determine if the noises come from the power-assisted steering system, it is
recommended to remove the V-ribbed belt of the vane pump and run the engine without vane
pump.
If the front axle is damaged as a result of an accident certain steering components must be
replaced Chapter.
No provision is made for repairing on the power-steering gear. If there are any complaints
about the steering gear, replace it.
t
t
t Only use semi-fluid gear lubricant AOF 063 000 04 to grease the gear rack (filling capacity
571
23 to 27 g).
t
t
1-
Oil type: hydraulic oil -G 002 000Oil quantity in the system: 0.7 ... 0.9 Itr.
Heat shield
572
2-
Nut, 23 Nm
3-
23 Nm
4-
5-
Gasket rings
6-
Hollow screw, 38 Nm
M14 x 1.5
7-
Nut, 23 Nm
8-
Fitting position:
t
9t
t
10 11 t
12 t
13 t
14 t
15 16 t
17 t
Power-steering gear
adjust Chapter
removing and installing Chapter
Assembly carrier
20 Nm + 90
replace after each removal
20 Nm + 90
replace after each removal
20 Nm + 90
replace after each removal
40 Nm + 90
replace after each removal
Pendulum support
20 Nm + 90
replace after each removal
100 Nm + 90
replace after each removal
573
18 t
100 Nm + 90
replace after each removal
19 t
Self-locking nut, 50 Nm
replace after each removal
20 -
21 -
Counternut, 50 Nm
22 -
Pressure line
23 -
Hollow screw, 38 Nm
M14 x 1.5
24 t
M16 x 1.5
25 t
Return-flow line
from the power-steering gear to the reservoir for central hydraulic oil
27 t
Gasket rings
replace after each removal
26 t
Hollow screw, 45 Nm
Sealing sleeve
28 t
29 -
20 Nm + 90
replace after each removal
Steering column universal joint
t Hydraulic oil -TL 52 146-, -N 052 146 00- e.g. -PENTOSIN CHF 11 S (G 002 000)-
574
1t
t
2t
t
3t
t
4t
t
5-
t
t
t
Gearbox jack with adapter, e.g. -V.A.G 1383A- with -V.A.G 1359/2-
Plastic screw plugs for line connections on the power-assisted steering gear (commercially
available)
t Hydraulic oil -TL 52 146-, -N 052 146 00- e.g. -PENTOSIN CHF 11 S (G 002 000)Note
t
t
Apart from replacing the bellows and the track rods, no provision is made for further
repairs.
Absolute cleanliness is required when working on the power steering.
t Thoroughly clean the connection points and their surroundings before releasing.
t
t
t
t
t
Place removed parts on a clean surface and cover if the repair cannot be carried out
immediately.
Do not use fluffy cloths.
Remove spare parts from their wrapping immediately before fitting.
Use only genuine wrapped parts.
Do not use drained hydraulic oil again.
Disposal Chapter.
Removing
576
577
578
Screw down the hexagon nut -1sufficiently until the track rod extractor
cannot damage the thread.
579
Install
580
vehicle.
Caliper gauge
t
t
Clamp pliers for hose clamp, e.g. -V.A.G 1275Semi-fluid gear lubricant -TL733-, -NO 52733 00- e.g. -DEA ORNA F6 EPO (AOF 063 000
04)Note
Always replace the steering components -Pos. 1- up to -Pos. 9- after an accident or in the
event of damage to the front axle.
No provision is made for repairing on the power-steering gear. The cause of any problems
t which may arise is determined by the pressure test and tightness test. If there is a fault,
replace the power-steering gear.
t
Only use steering gear grease -AOF 063 000 04- in order to grease the gear rack (filling
capacity 23 ... 27 g).
1t
check Anchor
Counternut, 50 Nm
3-
replace
tensioning Anchor
4-
Bellows
5t
t
t
6t
Power-steering gear
no provision made for repairs
removing and installing Chapter
adjust Chapter
Inspecting centre position Anchor
8-
9-
t
t
t
check Anchor
removing and installing Anchor
Check fitting position
585
The figure shows a version with the vane pump located at the bottom.
For a vane pump located at the top, the same tightening torques are valid for the fixing
t screws of the vane pump as well as for the hollow screw in order to connect the pressure
line to the vane pump.
1t
t
t
23t
4-
V-ribbed belt
before removing mark running direction
Assignment BookletOctavia
removing and installing Engine, Mechanics; Rep. gr.13
10 Nm + 90
Vibration damper
with the belt pulley for the V-ribbed belt
25 Nm
5-
Tensioning element
6-
Generator
586
7t
Support
The fig. shows a bracket for vehicles not fitted with air conditioning
8t
45 Nm
for securing the bracket -Pos. 7- at the engine block
9-
25 Nm
10 -
Hollow screw, 38 Nm
11 -
Sealing ring
replace
12 -
Pressure line
13 -
Sealing ring
replace
14 t
Vane pump
for power-assisted steering
15 -
25 Nm
16 -
Belt pulley
Note
t
t
17 -
Allan screw, 25 Nm
18 -
25 Nm
587
Note
The pressure switch screwed into the vane pump is used for the idling speed stabilisation of
the engine while moving the steering wheel when the vehicle is standing still.
1-
Vane pump
2-
Suction line
3-
Pressure line
4t
t
5t
Pressure switch, 15 Nm
switches at 4.0 MPa (40 bar)
Test signal Injection and Ignition System; Rep. gr.24
Sealing ring
replace
6-
Hollow screw, 38 Nm
7-
Sealing ring
t
8-
replace
Colour marking on suction line
t all around white or yellow, must be positioned inside the bracket (- Pos.9)
588
9-
Support
10 -
Nut
11 -
Support
t
t
Hose from the adapter set, e.g. -V.A.G 1402/6Hose clamp -MP 7-602Note
If there is insufficient hydraulic oil in the reservoir always check the power-assisted
steering system for tightness Chapter.
If there is a leak on the power-steering gear first check the lines/line connections for
tightness, if necessary retighten and wipe dry.
Inspecting the gasket ring on the steering pinion and on the gear rack seal Chapter. If
there are leaks on the gasket ring or on the gear rack seal replace the power-steering gear.
589
590
1-
Vane pump
2-
Sealing ring
t
345678t
910 t
11 t
12 t
13 -
Pressure switch
1-
Vane pump
2-
Sealing ring
t
34567-
8t
9-
Sealing ring
replace after each removal
Pressure line with banjo union
10 -
Hollow screw
Test requirements:
l
Inspection:
Remove the hose clamp -MP 7-602- from the suction line and return line.
Open the shut-off valve at the manometer.
Start the engine and replenish the hydraulic oil level in the reservoir if so required.
With the engine running at idling speed, close off the shut-off valve (no longer than 5
seconds), read off the pressure at max. steering angle and compare with the specified
value according to the following table.
Nominal pressure of the vane pump
Engine
MPa
bar
MPa
bar
Fuel engines
9,0
90
85 ... 95
Diesel engines
9,0
90
85 ... 95
Note
t If the specified value is exceeded or if it is not reached, replace the vane pump.
t
Remove and install the vane pump located at the top Chapter.
Remove and install the vane pump located at the bottom Chapter.
Pinch off the suction line and the return flow line with hose clamps -MP 7-602-.
594
Repairs on the vane pump are not foreseen. The cause of any problems which may be
t arising is determined by the pressure and tightness test. If there is a fault, replace the vane
pump.
The pumps supplied by the spare part storeroom are without oil. Therefore absolutely fill up
t with hydraulic oil before fitting -G 002 000- and turn by hand, otherwise noises or damage
to the pump could occur while driving.
t
t
t
t
t
t
Oil type: hydraulic oil -G 002 000Oil quantity in the system: 0.7 ... 0.9 ltr.
Remove spare parts from their wrapping immediately before fitting.
Use only genuine wrapped parts.
Do not use drained hydraulic oil again.
Replace gasket rings.
Mark the rotation direction before removing the V-ribbed belt. Reversing the rotation
t direction of an already used belt may destroy it. Pay attention to the correct position of the
V-ribbed belt in the belt pulley when installing it.
t
Disposal Chapter.
The version and the attachment of the vane pump as well as the bracket differ from the fig.
t according to the engine versions and thoses equipped with or without air conditioning
system.
Vehicles with 1.4/44 kW Engine:
t
Before removing, the fitting position of the belt pulley must be marked.
If the belt pulley of the vane pump is installed the wrong way round, it is displaced in
t relation to the other belt pulleys. The V-ribbed belt is damaged as a result of this
displacement.
t Hydraulic oil -TL52 146-, -N 052 146 00- e.g. -PENTOSIN CHF 11 S (G 002 000)Removing
595
The fig. shows the engine cover of the 1.9 Itr./66 kW (TDI) engine. The engine covers of the
other engine versions differ from the fig.
1-
Plug
2-
Clamp
3-
Bolt
597
Install
Note
598
Tightening torque: 25 Nm
Tightening torque: 25 Nm
599
t Hydraulic oil -TL52 146-, -N 052 146 00- e.g. -PENTOSIN CHF 11 S (G 002 000)Removing
Note
Mark the rotation direction before removing the V-ribbed belt. Pay attention to the correct
position of the V-ribbed belt in the belt pulley when installing it.
600
601
of paint.
t Do not use drained hydraulic oil again.
t
Tightening torque: 25 Nm
Vehicles with 1.4/44 kW Engine:
603
Tightening torque: 25 Nm
Chapter.
Disposing
of the
pumpequipment required
Special
tools
andvane
workshop
Note
The oils used in the vane pump do not contain any harmful substances. These oils may be
disposed of together with the drained engine and gearbox oil.
605