Brake Systems

Service
Workshop Manual
Amarok 2011
Brake systems
Edition 05.2013
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Service Department. Technical Information

Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
45 - Anti-lock brake system
46 - Brakes - mechanism
47 - Brakes - hydraulics
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Technical information should always be available to the foremen and mechanics, because their
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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and t. Cop py
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All rights reserved.

No reproduction without prior agreement from publisher.
Copyright 2013 Volkswagen AG, Wolfsburg D4B80305DED

Amarok 2011
Brake systems - Edition 05.2013
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Technical data for brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 General notes on ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Repair instructions for repair work on ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Components and fitting locations - (ABS, EDL, ASR, ESP) . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Control unit and hydraulic unit . . . . . . . . .e.n.A.G.. V. o.lk.s.w.ag. e.n.A.G. . . . . . . . . . . . . . . . . . . . . . . . 7
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3.1 Assembly overview - control unit andVohydraulic lksw unit . . . . . . . . e. s.n.ot.g. . . . . . . . . . . . . . . . . . 7
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3.2 Removing and installing ABS control ris
ed
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unit J104 and ABS hydraulic unitarN55 an
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.......... 9
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3.3 Removing and installing ABS au th control unit J104 without ABS hydraulic unit N55
or
ac
........ 11
3.4 Connecting brake lines tosshydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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4.1 Assembly overview - front axle speed sensors G45 / G47 . . . . . . . . . . . . . . . . . . . . . . . . 14
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4.2 Assembly overview - rear axle speed sensors G44 / G46 . . . . . . . . . . . . . . . . . . . . . . . . 15
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4.3 Removing and installing front axle speed sensors G45 / G47 . . . . . . . . . . . . . . . . . . . . . . 15
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4.4 Removing and installing rear axle speed sensors G44 / G46 . . . . . . . . . . . . . . . . . . . . . . 16
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46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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1 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.1 Assembly overview - front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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1.2 Removing and installing brake pads or linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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1.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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2.1 Assembly overview - rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.2 Removing and installing brake carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
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2.3 Removing and installing brake shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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2.4 Resetting drum brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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2.5 Removing and installing wheel brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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3 Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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3.1 Assembly overview - parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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3.2 Removing and installing handbrake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3.3 Removing and installing front handbrake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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3.4 Removing and installing rear handbrake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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3.5 Adjusting parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

4 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.1 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.2 Removing and installing brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1 Front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.1 Assembly overview - front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.2 Removing and installing brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.1 General notes on brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.2 Pre-bleeding hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Contents i
Amarok 2011
2.3 Bleeding hydraulic system following standard procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2.4 Subsequent bleeding of hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.5 Testing for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3 Brake booster and brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.1 Assembly overview - brake booster/brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . 50
3.2 Removing and installing brake booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.3 Removing and installing brake master cylinder . . . . . . . . . . . . .n.A.G.. V. o.lk.s.w.ag. e.n.A. . . . . . . . . . 53
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3.4 Removing and installing brake light switch F . . . . . . . V. o.lk.sw . a. . . . . . . . . . . . . . . . o.e.s n. o.t . . . 55
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4 Brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ri.se.d. . . . . . . . . . . . . . . . . . . . . . . . . . . . . r.ante56
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4.1 Assembly overview - flanging tool . . . . . . . . . a.u.t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
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4.2 Required tools . . . . . . . . . . . . . . . . . . . . . . .s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
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4.3 Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
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ii Contents
Amarok 2011
00 Technical data
1 Technical data
(VRL005543; Edition 05.2013)
1.1 Technical data for brakes, page 1
1.1 Technical data for brakes

Front brakes
Item Component
1 Brake caliper Double-piston floating cali
per disc brake (16")
2 Brake pad thick mm 12.5
ness (without
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Brake disc, mm 28 ce
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thickness pt
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Brake disc, mm 26 ab
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4 Brake piston in mm 2 x 48
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Rear brake (drum brake)

Item Component
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1 Wheel brake mm 26.99

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2 Brake lining, mm 55
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Brake lining, mm 6.7

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Brake lining, mm 1.25

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Brake master cylinder and brake booster
Brake master cylinder in mm 26.99

Brake booster (LHD vehicles) in inches 10" / 10" - tandem
Brake booster (RHD vehicles) in inches 10" / 10" - tandem
1. Technical data 1
Amarok 2011
2 Brake test
2.1 General information, page 2
2.2 Brake test, page 2
2.1 General information

The drive is provided by the test rig.
For vehicles with a manual gearbox, ensure that the gear lever
is in neutral for the test. For vehicles with an automatic gear
box, ensure that the selector lever is in N.
When conducting the test, observe the specifications provided
by the manufacturer of the test rig.
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The brake regulation systems do not function when ignitionauist off.
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The brake test must be performed on a regulated single-axle roller
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Regulated means that the speed of the brake test stand rollers is
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This prevents brake forces being transferred to the drive train.
Test speed should not exceed 6 km/h. Otherwise, the EDL control
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will activate the brakes if the rollers start at different speeds.
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The test rigs authorised by Volkswagen fulfil these requirements.
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2 Rep. gr.00 - Technical data

Amarok 2011
45 Anti-lock brake system

1 General information
1.1 General notes on ABS, page 3
1.2 Repair instructions for repair work on ABS, page 3
1.1 General notes on ABS

The ABS brake system is divided diagonally. The servo-assis
tance is effected pneumatically by the vacuum brake booster unit.
Faults in the ABS do not influence the brake system and servo
assistance. The conventional brake system remains functional
even without ABS. A change in braking behaviour is to be reck
oned with. After the ABS warning lamp - K47- comes on, the rear
wheels may lock prematurely.
ABS layout in left-hand drive vehicle:
1- Brake booster
2- Hydraulic unit and control unit
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The hydraulic unit -2- and control unit -1- form one component.
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Hydraulic pump -3- must not be separated from hydraulic unit.
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1.2 Repair instructions for repair work on

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Use Vehicle diagnostic tester for fault finding. Prote
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Disconnect battery earth strap with ignition switched off.
1. General information 3
Amarok 2011
Before carrying out welding work with an electric welding unit,

note General Information; Body Repairs, General Body Re
pairs .
When working with brake fluid, observe the valid, relevant
safety precautions and notes.
After work for which the brake system had to be opened, bleed
the brake system with brake filling and bleeding equipment -
VAS 5234- or -V.A.G 1869- page 46 .
During the final road test, ensure that a controlled brake test
is performed at least once (pulsations must be felt at the brake
pedal).
Absolute cleanliness is required when working on the anti-lock
brake system. Auxiliary items containing mineralgenoil,
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Thoroughly clean all unions and ttheho adjacent areas before
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loosening. Do not use aggressive au cleaning agents such as ac
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brake cleanser, petrol, thinners or similar.
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Place removed parts on a clean surface and cover.
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If repairs cannot be carried out immediately, carefully cover or
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Only use lint-free cloths.
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Only unpack replacement parts immediately prior to fitting.
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Only use genuine packed parts.
Do not work with compressed air if the system is open. Do not
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move the vehicle.
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During painting operations, the electronic control unit can be

exposed to a maximum temperature of 95 C only briefly, and
to a maximum of 85 C for longer periods (approx. 2 hours).
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Ensure that no brake fluid enters connectors. rm
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4 Rep. gr.45 - Anti-lock brake system

Amarok 2011
2 Overview of fitting locations

2.1 Components and fitting locations - (ABS, EDL, ASR, ESP),
page 5
2.1 Components and fitting locations - (ABS, EDL, ASR, ESP)
1 - Dash panel insert

Removing and installing
Electrical system;
Rep. gr. 90 ; Dash panel
insert; Removing and in
stalling dash panel in
sert .
Renewing Vehicle di
agnostic tester.
2 - Driving program button -
E598-
Location: in centre con
sole.
3 - TCS and ESP button - n AG. Volkswagen AG do
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Location: in centre con
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4 - Steering angle sender -
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G85- pt
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ESP.
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Location: on steering
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column between steer
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column switch.
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Electrical system;
Rep. gr. 94 ; Lights,
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bulbs, switches - exteri

or; Steering column
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switch
After installing, perform
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basic setting for steering

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angle sender - G85-

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Vehicle diagnostic
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tester.
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5 - Rear axle shaft with wheel bearing/wheel bearing unit

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The ABS sensor ring is installed on the rear axle shaft.

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6 - Rear right speed sensor - G44- / rear left speed sensor - G46- C py
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Can be tested using Vehicle diagnostic tester. yri
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7 - Front right speed sensor - G45- / front left speed sensor - G47-
Can be tested using Vehicle diagnostic tester.
Removing and installing page 15
8 - Wheel bearing
ABS sensor ring is installed in wheel bearing
9 - Brake light switch - F-
Including brake pedal switch - F47- .
2. Overview of fitting locations 5

Amarok 2011
10 - ABS hydraulic unit - N55-
The hydraulic unit consists of the components:
ABS return flow pump - V39-
Brake pressure sender 1 - G201-
Valve block (contains inlet and outlet valves)
ABS return flow pump - V39- and valve block must not be separated from one another.
Assembly overview page 7 .
11 - ABS control unit - J104-
Location: on hydraulic unit, on left in engine compartment
Can be tested using Vehicle diagnostic tester.
Do not separate connector before successfully completing self-diagnosis. Switch ignition off before sep
arating connector. gen AG
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The following components are integrated into the control unit: d by V gu
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Longitudinal acceleration sender - G251- or
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Lateral acceleration sender - G200- (only on vehicles
ss having ESP).
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Yaw rate sender - G202- (only on vehicles having ESP).
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Amarok 2011
3 Control unit and hydraulic unit

3.1 Assembly overview - control unit and hydraulic unit, page
7
3.2 Removing and installing ABS control unit J104 and ABS
hydraulic unit N55 , page 9
3.3 Removing and installing ABS control unit J104 without ABS
hydraulic unit N55 , page 11
3.4 Connecting brake lines to hydraulic unit, page 13
3.1 Assembly overview - control unit and hydraulic unit
1 - Brake servo
With brake master cylin
der and brake fluid res
ervoir
page 51
2 - Connection for brake line
From primary piston cir
cuit of brake master cyl
inder to hydraulic unit.
14 Nm
Hydraulic unit to primary
piston circuit of brake
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Identification: union nut yV
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with thread M12 x 1 ir se
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4 - ABS hydraulic unit - N55-
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with ABS control unit - J104-
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ABS return flow pump -
rm
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When replacing the hy
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draulic unit, always seal t to the co

the old part with plugs
from the repair kit
Electronic Parts Cata
rrectness of i
logue (ETKA) .
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ABS hydraulic unit -
N55- with ABS control
nform
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unit - J104-
page 9 .
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Removing and installing ABS control unit - J104- without ABS hydraulic unit - N55- page 11 .
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To rear left wheel brake cylinder
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Identification: union nut with thread M12 x 1
AG.
14 Nm
3. Control unit and hydraulic unit 7

Amarok 2011

To rear right wheel brake cylinder
14 Nm
Hydraulic unit to secondary piston circuit of brake master cylinder
14 Nm
From hydraulic unit to front right brake caliper.
14 Nm
From hydraulic unit to front left brake caliper.
14 Nm
From secondary piston circuit of brake master cylinder to hydraulic unit.
14 Nm wage
es
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Brake systems ac
- Edition 05.2013
ce
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pt
3.2 Removing and installing ABS control
an
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unit - J104- and ABS hydraulic unit -
ab
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N55-
wit
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Special tools and work
spec
shop equipment re urposes, in part or in wh
t to the co
quired
Brake pedal depres
sor - V.A.G 1869/2-
rrectness o
cial p
f inform
mer
atio
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Torque wrench -
ht
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V.A.G 1410-
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Sealing plug repair kit

Location:
The ABS control unit -
J104- is bolted to the
ABS hydraulic unit - N55-
and is located on the left
in the engine compart
ment.
WARNING
Do not bend the brake

lines in the area of the
hydraulic unit!
Removing
Read out and note
the existing control
unit code.
Disconnect battery
Electrical system;
Rep. gr. 27 ; Discon
necting and recon
necting battery .

Amarok 2011
Connect bleeder bot

tle hose to front left
brake caliper bleeder
valve and open
bleeder valve.
Use brake pedal ac
tuator - V.A.G
1869/2- to press on
brake pedal.
Close front left bleed
er valve.
Place sufficient lint-
free cloths under the
control unit and hy
draulic unit.
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Ensure no brake fluid Volkswa not
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Unscrewssbrake lines -2- to -7- from ABS hydraulic unit - N55-ac .
a
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Seal brake lines and threaded holes using sealing plugs from
pt
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sealing plug repair kit Electronic Parts Catalogue (ETKA) . an

itte
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Unlock connector from ABS control unit - J104- in ab

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-direction of arrow- and pull it off forwards. wit

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Raise vehicle Maintenance ; Booklet ; Descriptions of work;
hole
spec
Raising vehicle .
es, in part or in w
t to the co
rrectness of i
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d b ua
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Remove
utho bolts -arrows-. or
a ac
ss
Remove ABS hydraulic unit - N55- -1- upwards from bracket/
ce
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frame -2-.
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Installing
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Installation is performed in reverse sequence; note the following:
wit
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Note
es, in part or in w
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Remove sealing plugs from new hydraulic unit only when the
corresponding brake line is to be fitted.
rrectness of i
If sealing plugs are removed too early from the hydraulic unit,
l purpos
brake fluid can escape, and it can then no longer be guaran

teed that the unit can be sufficiently filled and bled.
nform
mercia
Caution
at
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It must be possible to screw brake line nuts to end of threads
his
ate
into ABS hydraulic unit - N55- by hand.
do
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Only then may the nuts be tightened to the specified torque.

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Remove brake pedal depressor - V.A.G 1869/2- .
p by
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Bleed brake system page 46 . Prote AG.
Code ABS control unit - J104- using Vehicle diagnostic test

er.
Specified torques
3.1 Assembly overview - control unit and hydraulic unit,
page 7
3.3 Removing and installing ABS control

unit - J104- without ABS hydraulic unit -
N55-
Special tools and workshop equipment required
Torque wrench - V.A.G 1410-
Location:
The ABS control unit - J104- is bolted to the ABS hydraulic unit -
N55- and is located on the left in the engine compartment.

Amarok 2011
WARNING
Do not bend the brake lines in the area of the hydraulic

unit!
Neither moisture nor particles of dirt may enter the interior
of the control unit.
Avoid electrostatic charge!
Removing
Note
The hydraulic lines remain connected.
Follow the instructions for repair work on the anti-lock braking

system page 3 .
Read out and note the existing control unit code Vehicle
diagnostic tester.
Disconnect battery Electrical system; Rep. gr. 27 ; Discon
necting and reconnecting battery .
Release electrical connector.
Note
AG. Volkswagen AG d
The ABS control unit - J104- is removed downwards.olkswagen oes
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Loosen bolted connections -2- on ABS control unit - J104- /

h re
ABS hydraulic unit - N55- . Then, remove ABS control unit -

hole
spec
J104- -1-.
es, in part or in w
t to the co
Installing
rrectness of i
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Note
Valve calibration must always be carried out after MK25A system

nform
ercia
has been disconnected. This does not affect the MK25E Vehicle
m
diagnostic tester.
at
om
ion
c
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or
Code ABS control unit - J104- using Vehicle diagnostic test

his
ate
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do
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Specified torque
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Component Specified torque
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Bolted connection ABS control 4 Nm
co Vo
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unit - J104- / ABS hydraulic unit
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Prote AG.
- N55-

Amarok 2011
3.4 Connecting brake lines to hydraulic unit

On brake master cylinder
A - Secondary piston circuit of brake master cylinder to hydraulic
unit.
B - Primary piston circuit of brake master cylinder to hydraulic unit.
On hydraulic unit:
A - From hydraulic unit to secondary piston circuit of brake master
cylinder.
B - From hydraulic unit to primary piston circuit of brake master
cylinder.
1 - From hydraulic unit to front left brake caliper.
2 - From hydraulic unit to front right brake caliper.
3 - Hydraulic unit to rear left wheel brake cylinder
4 - Hydraulic unit to rear right wheel brake cylinder
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Amarok 2011
4 Sensors
4.1 Assembly overview - front axle speed sensors G45 / G47
, page 14
4.2 Assembly overview - rear axle speed sensors G44 / G46
, page 15
4.3 Removing and installing front axle speed sensors G45 /
G47 , page 15
4.4 Removing and installing rear axle speed sensors G44 /
G46 , page 16
4.1 Assembly overview - front axle speed sensors - G45- / -G47-
1 - Bolt
20 Nm
2 - Brake disc
3 - Wheel hub
4 - Retaining ring
Secures wheel bearing
in wheel bearing hous n AG. Volkswagen AG do
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5 - Wheel bearing o
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wheel bearing
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6 - Wheel bearing housing y li

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7 - Front right speed sensor - wit

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G45- / front left speed sensor -

h re
G47-
hole
spec
Before inserting speed

es, in part or in w
t to the co
sensor , clean inner sur

face of hole and coat it
with polycarbamide
rrectness of i
grease Electronic
Parts Catalogue (ET
l purpos
KA) .
nform
ercia
page 15
m
8 - Bolt
at
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8 Nm
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Amarok 2011
4.2 Assembly overview - rear axle speed sensors - G44- / -G46-
1 - Brake backplate
Reset brake before re
moving brake drum
page 31
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2 - Bolt agen oes
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Always renew after re ised b ara
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150 Nm +90 ss c
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pt
3 - Axle beam
du
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4 - Speed sensors - G44- / -
erm
ab
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G46- ot p
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Before inserting speed
h re
sensor , clean inner sur
hole
spec
face of hole and coat it
es, in part or in w
with polycarbamide
t to the co
grease Electronic
Parts Catalogue (ET
KA) .
rrectness of i
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page 16
5 - Bolt
nf
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8 Nm
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6 - Rear axle shaft

o
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With wheel bearing/
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wheel bearing unit and
sd
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sensor ring -arrow- for

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ABS
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Cop py
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4.3 Removing and installing front axle

speed sensors - G45- / -G47-
Polycarbamide grease Electronic Parts Catalogue (ETKA) .
4. Sensors 15
Amarok 2011
Removing
Raising vehicle .
Pull connector -1- of speed sensor wire off speed sensor -2-.
Remove bolt -arrow- from wheel bearing housing.
Pull speed sensor -2- out of wheel bearing housing.
Installing
Before inserting speed sensor , clean inner surface of hole,
and coat speed sensor all-round with polycarbamide grease
Electronic Parts Catalogue (ETKA) .
Insert speed sensor into hole in wheel bearing housing, and
tighten bolt.
Push connector of speed sensor wire onto speed sensor .
Turn steering to full left and right lock and check clearance to
speed sensor wire. . Volkswage n AG n AG d
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Specified torques Volks not
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4.1 Assembly overview - front
oris axle speed sensors G45 / nte
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G47 , page 14 s au ra
c
s
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pt
4.4 Removing and installing rear axle speed
du
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sensors - G44- / -G46-
erm
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spec
es, in part or in w
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nform
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at
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c
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ate
do
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Polycarbamide grease Electronic Parts Catalogue (ETKA) .

p
cum
for
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Removing
t.
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Cop py
. rig
ht ht
rig by
py
Raising vehicle . co Vo
by lksw
cted agen
Prote AG.

Amarok 2011
Pull connector -2- off speed sensor -1-.
Remove bolt -arrow-.

Pull speed sensor out of axle beam.
Installing
Before inserting speed sensor , clean inner surface of hole,
and coat speed sensor all-round with polycarbamide grease
Electronic Parts Catalogue (ETKA) .
Insert speed sensor into hole in axle beam, and tighten bolt.
Push connector of speed sensor wire onto speed sensor .
Specified torques
4.2 Assembly overview - rear axle speed sensors G44 / G46
, page 15
AG. Volkswagen AG d
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ab
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es, in part or in w
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rrectness of i
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4. Sensors 17
Amarok 2011
46 Brakes - mechanism
1 Front brakes
1.1 Assembly overview - front brakes, page 18
1.2 Removing and installing brake pads or linings,
page 19
1.3 Removing and installing brake caliper, page 22
1.1 Assembly overview - front brakes
Note
After replacing brake pads/linings, depress brake pedal firmly several times with
en AG. V
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wagen AGstationary so that
the brake pads/linings are properly seated in their normal operating
olks position.
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Use brake filling and bleeding equipment - VAS 5234- or upgrade
ir se kit and extraction unit - V.A.G 1869/4- nte to
extract brake fluid from brake fluid reservoir. aut
ho eo
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Before removing a brake caliper or disconnecting a brake hose, fit brake pedal depressor - V.A.G 1869/2-
ce
le
un
(when doing this, release pressure in system).
pt
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1 - Wheel bearing housing
wit
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With wheel bearing and
hole
spec
wheel hub
es, in part or in w
t to the co
2 - Bracket
For brake hose and
speed sensor wire
rrectness of i
3 - Bolt
l purpos
For bracket on wheel

bearing housing
nform
ercia
9.5 Nm
m
a
com
t
4 - Splash plate
ion in
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5 - Brake disc
thi
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Internally ventilated do
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fo
Brake disc 303 mm

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Thickness: 28 mm t. Cop py
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Wear limit: 26 mm.
ht
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When worn, renew on
by
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both sides of axle.
AG.
Unscrew brake caliper

prior to removing.
Never remove brake
discs from wheel hub by
force. If necessary use
penetrating fluid, be
cause otherwise brake
discs can be damaged.
6 - Bolt
20 Nm
7 - Bolt
9.5 Nm
18 Rep. gr.46 - Brakes - mechanism

Amarok 2011
8 - Brake pads
Thickness: 12.5 mm not including backplate.
Pad wear limit: 2 mm without backplate (remaining pad thickness)
Check thickness Maintenance ; Booklet ; Descriptions of work; Brake system: Conducting visual
examination for leaks and damage
Always replace on both sides
9 - Pad retainer
Always renew when changing pads.
10 - Brake carrier
With guide pins and protective caps
Bolt to wheel bearing housing.
Supplied as genuine part, assembled with sufficient grease on guide pins.
If protective caps or guide pins are damaged, install repair kit and use lubricant sachet supplied to lu
bricate guide pins
Installation position of guide pins page 19
11 - Brake caliper
12 - Bolt
Always renew after removing
65 Nm
13 - Brake hose
Install without twisting
Specified torque when being secured to brake caliper: 14 Nm (pipe with union nut).
Specified torque when being secured to brake caliper: 17 Nm (threaded pipe).
14 - Bolt
Always renew after removing n AG. Volkswagen AG do
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150 Nm +90 by
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tho or
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Installation position of guide pins
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un
pt
Guide pin -1- with notch -arrow- must be installed in brake

an
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carrier -3- at top (inlet side).

rm
ab
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ility
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wit
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Note
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hole
spec
es, in part or in w
If protective caps -2- or guide pins -1- and -4- are damaged, install
t to the co
repair kit and use lubricant sachet supplied to lubricate guide pins.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
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s
iva
do
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1.2 Removing and installing brake pads or

fo
en
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t.
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linings
Co
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Special tools and workshop equipment required cop Vo
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Prote AG.
1. Front brakes 19
Amarok 2011
Piston resetting appliance - T10145-
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Caution
ce
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nl
pt
du
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Mark brake pads when removing if they are to be reused. Fit

erm
ab
in same position when installing, or braking will be uneven.

ility
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wit
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hole

spec
es, in part or in w
Raising vehicle .
t to the co
Remove front wheels.

rrectness of i
Note
l purpos
Removal and installation of brake pads is shown for left side of

front axle only. Brake pad removal and installation on right side
nf
ercia
of front axle are analogous.

rm
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om
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Prote AG.

Amarok 2011
Removing
Remove bolts -arrows- for securing brake caliper with spanner
-1- (15 mm). When doing this, counterhold on guide pin using
open jaw spanner -2- (21 mm).
Remove brake caliper from brake carrier.
Secure brake caliper with wire so that the weight of the brake
caliper does not stress or damage the brake hose.
Remove brake pads -A- from brake carrier sideways.

AG. Volkswagen AG d
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Then remove pad retainers from brake carrier. Volksw
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Clean brake caliper housing. orise nte
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WARNING
ce
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un
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an
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Do not blow out brake system with compressed air; the result
rm
ab
ing dust constitutes a health hazard!
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
Only use methylated spirits to clean brake caliper housing.
rrectness of i
Installing
l purpos

nform
ercia
Before inserting new brake pads, press piston back into cylinder
using piston resetting tool - T10145- . Before pressing piston
m
back, draw off brake fluid from brake fluid reservoir with bleeder
com
tion in
bottle. Otherwise, fluid can overflow and cause damage, particu

r
te o
thi
larly if reservoir has been topped up.

s
iva
do
r
rp
cum
Place a piece of wood -2- or a brake pad in the recess so that

fo
en
ng
both pistons are pressed back at the same time.

t.
yi Co
Cop py
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Press both pistons back with piston resetting tool - T10145- yri
gh by
ht
-1-. cop Vo
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Prote AG.
1. Front brakes 21
Amarok 2011
Insert pad retainers -A- into brake carrier -B-. wage

es n
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ir se tee
Note utho
or
a ac
ss
Always renew pad retainers -A- when changing pads.
ce
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un
pt
an
d
itte
Fit pad retainers with chamfered projection -arrows- outward
y li
rm
ab
on brake carrier.
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
Insert brake pads -A- into pad retainers of brake carrier.
a
com
tion in
Fit brake caliper onto brake carrier and tighten securing bolts.
r
te o
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s
iva
Fit wheels.
do
r
rp
cum
fo
en
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t.
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Note Cop py
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After replacing brake pads/linings, depress brake pedal firmly
co Vo
by lksw
cted
several times with vehicle stationary so that the brake pads/
agen
Prote AG.
linings are properly seated in their normal operating position.
Check brake fluid level after changing brake pads.
Specified torques
Wheels, tyres; Specified torque for wheel bolts Rep. gr. 44 ;
Specified torque for wheel bolts .
1.3 Removing and installing brake caliper

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

AG. Volkswagen AG d
agen oes
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by
Vol not
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d ara
orise Brake ntesystems - Edition 05.2013
h eo
aut ra
c
Removing ss
ce
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un
pt
an
d
itte
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Note
erm
ab
ility
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wit
This procedure applies only to exchanging or the following repair is n
h re
work on the brake caliper.
ole,
spec
t to the co
Raising vehicle .
Remove front wheels.
rrectne
Connect bleeder bottle hose to brake caliper bleeder valve and
open bleeder valve.
ss o
cial p
f
Then apply brake pedal actuator - V.A.G 1869/2- .
inform
mer
Following this, close bleeder valve and remove bleeder bottle.
atio
om
Unscrew brake hose.
n
c
i
or
n thi
e
Remove bolts -arrows- for securing brake caliper with spanner

t
sd
va
-1- (15 mm). When doing this, counterhold on guide pin using
i
o
pr
cum
r
open jaw spanner -2- (21 mm).

fo
en
ng
t.
yi Co
Remove brake caliper from brake carrier. Cop py
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Installing p by
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cted agen
Installation is performed in reverse sequence; note the following: Prote AG.
The pistons are pressed back.

The brake pads are seated on the brake carrier.
Fit brake caliper on brake carrier.
Bolt brake hose to brake caliper.
Remove brake pedal actuator - V.A.G 1869/2- .
Bleed brake system page 46 .
Fit wheels.
Note
Firmly depress brake pedal several times with vehicle station

ary so that the brake pads are properly seated in their normal
operating position.
Check brake fluid level.
Specified torques
1. Front brakes 23
Amarok 2011
2 Rear brakes
2.1 Assembly overview - rear brakes, page 24
2.2 Removing and installing brake carrier, page 27
2.3 Removing and installing brake shoes, page 28
2.4 Resetting drum brakes, page 31
2.5 Removing and installing wheel brake cylinder, page 33
2.1 Assembly overview - rear brakes
Note
After renewing wheel brake cylinder, brake carrier and brake shoes, basic setting of the adjuster needs to
be performed page 31 . Then, with vehicle stationary and brake drum installed, depress brake pedal
firmly 10 times so that the brake shoes are properly seated in their normal operating position.
After work for which the brake system had to be opened, bleed the brake system with brake charge and
bleed system - VAS 5234- or extraction unit -V.A.G 1869/4- .
Before removing a wheel brake cylinder or brake backplate or disconnecting a brake line from the wheel
brake cylinder, fit brake pedal depressor - V.A.G 1869/2- (release pressure in system).
G. Volkswagen nA AG do
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1 - Bolt oris tee
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20 Nm ss
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2 - Brake drum
du
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Clean carefully and

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check for wear, dam

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spec
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Brake drum diameter:

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295 mm
Wear limit: 296.5 mm.
rrectness of i
Check wear limit using

brake drum calliper
l purpos
gauge - VAS 6787-

Reset brake before re
nform
ercia
moving brake drum

page 31
m
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io
3 - Rear axle shaft

n
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or
With wheel bearing/

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ate
wheel bearing unit and

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sensor ring for ABS

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rear right speed sensor C py
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- G44- / rear left speed rig ht
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sensor - G46-
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page 16
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Do not remove for re

newing brake shoes or
wheel brake cylinder
4 - Axle beam
5 - Compensator
6 - Handbrake cable front

Amarok 2011
page 35
7 - Handbrake cable rear right
To week 25/2011: secured on rear axle with a spring
From week 25/2011: revised handbrake cable, spring discontinued
8 - Adjustment nut
Adjusting handbrake page 38 .
9 - Handbrake cable rear left
To week 25/2011: secured on rear axle with a spring
From week 25/2011: revised handbrake cable, spring discontinued
10 - Bolt
For rear handbrake cable on brake carrier
9.5 Nm
11 - Bolt n AG. Volkswagen AG do
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For wheel by Vbrake cylinder on brake carriert gua
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8 Nm ho
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12 - Cap
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Unclip from brake carrier

un
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Reset brake shoes through this opening before removing brake drum
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13 - Brake line
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14 Nm
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spec
14 - Brake backplate
es, in part or in w

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15 - Wheel brake cylinder

Check for leaks page 26 .
rrectness of i

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16 - Bolt
Self-locking (micro-encapsulated)
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Clean residual locking fluid out of threaded hole in axle beam

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Threaded holes into which self-lock
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cleaned (e.g. using a thread chas
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er). Otherwise, there is a risk that
bolts will shear off when removed
once again.
30 Nm
17 - Brake shoe
Installed at rear in direction of travel
Wear limit page 1
18 - Brake shoe with lever for handbrake
Installed at front in direction of travel
2. Rear brakes 25
Amarok 2011
Wear limit page 1
Removing and installing page 28 AG. Volkswagen AG d
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19 - Compression spring d b ara
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20 - Spring plate aut ra
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To remove, push against compression spring and turn through 90.
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21 - Plunger rod
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Note correct installation position page 30
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Adjusters on plunger rod differ
es, in part or in w
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according to whether they have
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depending on the installation po
sition.
rrectness of i
Adjuster marked L (left-hand
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thread) belongs on right of vehi

cle, and vice versa.
nform
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22 - Upper return spring

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Note installation position: steeply offset side points towards lever for handbrake.
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23 - Adjuster spring
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Engage in lever Item 24 (page 26) with longer end of leg.

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Secures adjusters on plunger rod to prevent them from turning back.
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Must be carefully pushed away from adjuster (towards brake drum) when brake shoes are reset.
AG.
25 - Lower return spring

Note installation position: openings in hooks point towards brake carrier.
26 - Bolt
For rear axle shaft on axle beam
150 Nm +90
27 - Shoe steady pin
Checking wheel brake cylinder for leaks

Lift off dust boot with removal wedge - 3409- .
If brake fluid is found in the dust boot, renew wheel brake cyl
inder.
Ensure the dust boot is not damaged when lifting off.

Amarok 2011
Assembly overview - wheel brake cylinder

1- Dust cap; fit onto bleeder valve AG. Volkswagen AG d
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2- Bleeder valve; before screwing in, applybthiny V coat of assem
ol not
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3- Wheel brake cylinder ss a ra
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Note
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Renew wheel brake cylinder in case of leaks or if damaged.
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Specified torque
spec
es, in part or in w
t to the co
Component Specified torque
Bleeder valve in wheel brake 8 Nm
cylinder
rrectness of i
l purpos
2.2 Removing and installing brake carrier
nform
ercia
Removing
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Raising vehicle .
n in
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Remove rear wheels.
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Resetting brake and removing brake drum page 31 .
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Remove brake shoes page 28 .
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Remove wheel brake cylinder page 33 .
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Remove rear axle shaft Running gear, axles, steering; Rep.
cted agen
Prote AG.
gr. 42 ; Rear axle shafts .
2. Rear brakes 27
Amarok 2011
Remove bolt -A- and take brake carrier off axle beam.
Installing
Note
Before installing brake carrier, clean threaded hole for bolt

-A- in axle beam.
Threaded holes into which self-locking bolts or bolts with lock
ing fluid have been screwed must be cleaned (e.g. using a
thread chaser). Otherwise, there is a risk that bolts will shear
off when removed once again.
Insert 2 securing bolts -B- for rear axle shaft so that holes
-arrows- of brake carrier are centred on axle beam.
Tighten new bolt -A-. AG. Volkswagen AG d

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Bleed brake system page 46 . olksw not
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Specified torques hor eo
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2.1 Assembly overview - rear brakes, page 24 ss c
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Rear axle shafts; Assembly overview - rear axle shafts
an
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Running gear, axles, steering; Rep. gr. 42 ; Assembly over
y li
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view - rear axle shafts .
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2.3 Removing and installing brake shoes
t to the co
rrectne
Hook - 3438-
ss o
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Lubricating paste Electronic Parts Catalogue (ETKA) . Prote AG.
Removing
Raising vehicle .
Remove rear wheels.

Amarok 2011
AG. Volkswagen AG d
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Removal and installation
orise
of brake shoes is shown for left side
nte
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of rear axle only.
ut Brake shoe removal and installation on right or a
h
a
side are analogous.
ss c
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un
pt
Use only methylated spirits for cleaning the brake system.
an
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WARNING
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spec
Do not blow out brake system with compressed air; the result
ing dust constitutes a health hazard!
t to the co
Turn back adjustment nut -5- on front handbrake cable -1-.
rrectnes
Note
s o
cial p
f inform
-Pos. 2 4- are not relevant.
mer
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Prote AG.
Detach adjuster spring -A- from front brake shoe and remove
it from lever -B- -arrow-.
Remove lever -B-.
Remove spring plate -1- with springs.

Then lift rear brake shoe -2- in front of support plate -3-.
Unhook lower return spring -4-.
Detach handbrake cable -5- from front brake shoe -6-.
Guide brake shoes out together with plunger rod and return
spring upwards between wheel hub and wheel brake cylinder.
2. Rear brakes 29
Amarok 2011
Removing and installing upper return spring -1- and plunger rod
-2- from brake shoes.
Turn back pinion of adjuster -arrow A-.
Note
Adjusters on plunger rod differ according to gwhether

en AG. V they
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a right-hand or left-hand thread, depending
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Adjuster marked R -arrowaB-
ut belongs on left of vehicle, and
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vice versa. ss c
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Unhook complete plunger rod -2- and upper return spring -1-
itte
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from brake shoes -3- and -4-.
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Assemble plunger rod as follows:
wit
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Place thermoclip -6- and end piece -7- onto plunger rod -5-
hole
spec
with adjuster. Make sure that projection -arrow C- is inserted
es, in part or in w
into notch -arrow D-.
t to the co
Hook in upper return spring.
rrectness of i
Note installation position: steeply offset side of spring points
in direction of travel, towards lever for handbrake -4-.
l purpos
Then insert plunger rod.
nf
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Insert brake shoes into lower notches in plunger rod.
orm
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Installing
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Handbrake cable -A- must be within support plate bracket thi

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-B-.
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Grease contact surfaces for brake shoes on support plate

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-arrow 2- and on brake carrier -arrow 1- (qty. 6 distributed
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around circumference) with lubricating paste Electronic t. C rig
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Parts Catalogue (ETKA) . yri
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Guide brake shoes in together with plunger rod and return
agen
Prote AG.
spring from top between wheel hub and wheel brake cylinder.
Fit brake shoes onto wheel cylinder pistons.
Note
Do not damage dust protection shields on wheel brake cylinder!
Hook handbrake cable -5- onto lever.

Then place front brake shoe -6- behind lower support -3-.
Hook in lower return spring -4-.
Note installation position: openings in hooks point towards
brake carrier.
Then lift rear brake shoe -2- behind support plate -3-.
Install compression spring with spring plate -1-.

Amarok 2011
lkswage es n Brake systems - Edition 05.2013
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ed rante
Install lever -B- and hook
tho
ris in adjuster spring -A-, as illustrated eo
-arrow-. au ra
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ss
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Note
itte
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Handbrake must be released.
wit
is n
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If a used plunger rod is installed, it must be checked for ease
ole,
spec
of movement and cleaned if necessary.
t to the co
rrectne
Perform basic setting.
Use adjuster pinion -1- to set brake shoes to dimension
ss
-a- = 294 mm.
o
cial p
f inform
mer
Caution
atio
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i
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If distance -a- is too small then plunger rod might slip out of
thi
e
brake shoe guide when brake is first applied, leading to mal

t
sd
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function.
pr
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Install brake drum.
t. C rig
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Vo
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Firmly depress brake pedal 10 times.
c by lksw
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Prote AG.
Fit wheels.
Adjust handbrake page 38 .
Specified torques
2.4 Resetting drum brakes

Hook - 3438-
2. Rear brakes 31
Amarok 2011
Brake drum calliper gauge - VAS 6787-
Procedure AG. Volkswagen AG d

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Raise vehicle Maintenance ; Booklet ; Descriptions ofsework;
db
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Raising vehicle . thori
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Remove rear wheels. ss
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The handbrake is released.
an
itte
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Unclip sealing cover -arrow- from brake drum.
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spec
es, in part or in w
t to the co
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atio
Pass a hook , e.g. -3438- through a threaded hole for wheel
om
bolts in brake drum/wheel hub to pull lever -B- carefully in
n in
or c
-direction of arrow-.
thi
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The guide a short screwdriver -A- through opening in brake

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carrier and position against pinion of adjuster -C-.

m
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Prote AG.
Note
For reasons of clarity, brake drum is removed in illustration.

If necessary, brake drum can also be removed without reset
ting brake shoes.
To press lever away from adjuster, it is also possible to insert
a second screwdriver into opening -B- in brake carrier. This
can be used to press lever towards brake drum.
Use screwdriver -A- to turn adjuster in -direction of arrow-. This

causes pinion of adjuster to be turned upwards.

Amarok 2011
AG. Volkswagen AG d Brake systems - Edition 05.2013
agen oes
olksw not
V
Due to corrosion, it may be necessary
ed
by to press brake drum off gu
ara
wheel hub. horis nte
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Screw 2 bolts M 8 -A- into
s threaded holes in brake drum and
s c
ce
1
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tighten one then the other by a / turn at a time. 2
nl
pt
du
an
itte
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Check wear limit of brake drum using brake drum calliper
erm
ab
gauge - VAS 6787- .
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
2.5 Removing and installing wheel brake
cylinder
l purpos
nform
ercia
Brake pedal depressor - V.A.G 1869/2-

m
at
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ion
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or
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ate
do
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for
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Cop py
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rig ht
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Prote AG.
Removing
Raising vehicle .
Remove rear wheels.
Connect bleeder bottle hose to wheel brake cylinder bleeder
valve and open bleeder valve.
Then apply brake pedal actuator - V.A.G 1869/2- .
Following this, close bleeder valve and remove bleeder bottle.
Remove brake line -1- from wheel brake cylinder.
Remove brake shoes page 28 .
Remove bolts -2- for wheel brake cylinder on brake carrier and
take off wheel brake cylinder.
Installing
Install brake shoes and brake drum page 28 .
Specified torques
2. Rear brakes 33
Amarok 2011
3 Handbrake
3.1 Assembly overview - parking brake, page 34
3.2 Removing and installing handbrake lever, page 34
3.3 Removing and installing front handbrake cable,
page 35
3.4 Removing and installing rear handbrake cable,
page 36
3.5 Adjusting parking brake, page 38
3.1 Assembly overview - parking brake
1 - Handbrake lever trim

Release page 35 .
2 - Nut
For front handbrake ca
ble on handbrake lever
3 - Handbrake lever
page 34
4 - Handbrake warning switch
- F9-
5 - Handbrake cable front
page 35
Adjusting page 38 .
6 - Nut
For handbrake lever on n AG. Volkswagen AG do
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ility
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t to the co
rrectness o
cial p
f inform
mer
3.2 Removing and installing handbrake lev

atio
m
er
o
n
c
i
or
n thi
te
Removing
sd
iva
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pr
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Remove centre console General body repairs, interior; Rep.

fo
en
ng
gr. 68 ; Compartments, covers and trims; Removing centre

t.
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console . C py
t. rig
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pyri by
Vo
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cted agen
Prote AG.

lkswage es n
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byV ua Amarok 2011
d ran
ir se
tho tee
or Brake systems - Edition 05.2013
au ac
ss
Unlock tab in rear lower area of handle with a screwdriver
ce
le
un
pt
-1-.
an
d
itte
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erm
Then pull trim -2- off handbrake lever in -direction of arrow-.
ab
ility
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spec
t to the co
rrectness o
Handbrake lever -1- is in its lowest position, and is not applied.
cial p
f inform
Pull connector -3- off handbrake warning switch - F9- -2-.
mer
atio
m
Unscrew nut -4-.

o
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c
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te
sd
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pr
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fo
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Cop py
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pyri by
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by
cted agen
Prote AG.
Unscrew nut -A- from front handbrake cable -B-.

Unscrew nut -C-.
Press both projections -arrows- together with pliers and re
move handbrake lever. Thread front handbrake cable out at
same time.
Installing
Nut -A- must be screwed over end of front handbrake cable
-B-.
Specified torques
Installing centre console General body repairs, interior;
Rep. gr. 68 ; Compartments, covers and trims; Installing cen
tre console .
3.3 Removing and installing front hand

brake cable
Removing
Remove handbrake lever page 34 .
Raising vehicle .
3. Handbrake 35
Amarok 2011
Unhook front handbrake cable -A- from bracket -B- and pull
out downwards with grommet -arrow-.
AG. Volkswagen AG d
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olksw not
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Unscrew adjustment nut -5- from front handbrake cable -1-.
t to the co
Note
rrectne
Handbrake cables at rear left -2- and right -3- remain in compen
sator -4-.
ss o
cial p
f i
Using pliers, press together both locking projections on cable
nform
support bracket -arrow A- of front handbrake cable, and re
mer
atio
move handbrake cable -1- from cable support bracket.
om
n
c
i
Installing
or
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a

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fo
Locking projections on cable support bracket -arrow A- of front
en
ng
t.
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handbrake cable must be horizontal after installation.
Co
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Install handbrake lever page 34 .
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agen
Prote AG.
Specified torques
Installing centre console General body repairs, interior;
Rep. gr. 68 ; Compartments, covers and trims; Installing cen
tre console .
3.4 Removing and installing rear handbrake

cable
Removing
Raising vehicle .
Remove rear wheels.

Amarok 2011
Unscrew adjustment nut -5- from front handbrake cable -1-.

Unhook corresponding handbrake cable at rear left -2- or right
-3- from compensator -4-.
Using pliers, press together both locking projections on cable
support bracket -arrow B- of corresponding rear handbrake
cable, and remove handbrake cable from cable support brack
et.
Push spring -1- of handbrake cable back in

-direction of arrow- and hold it with pliers.
Unhook handbrake cable -2- from lever
wage
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Remove cable ties -arrows- for speed sensor wire from hand
es, in part or in w
brake cable.
t to the co
Remove bolts -A- and take handbrake cable off brake carrier.
rrectness of i
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Then pull handbrake cable -A- out of brackets on frame, pull

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out and remove body -arrows-.

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Installing
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Installation is performed in reverse sequence; note the following: by c lksw
cted agen
Prote AG.
3. Handbrake 37
Amarok 2011
Handbrake cable -A- must be within support plate bracket

-B-.
Note
For reasons of clarity, brake shoes are removed in illustration.

-Arrow 1- and -arrow 2- are not relevant.
Tighten bolts -A- to specified torque.

Fit new cable ties -arrows- for speed sensor wire on handbrake
cable. . Volkswagen AG
gen AG d wa oes
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ab
ility
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Take handbrake cable that is to be installed at rear left -2- or
spec
right -3- and hook it into compensator -4-.
es, in part or in w
t to the co
Locking projections on cable support bracket -arrow B- of rear
handbrake cables must be horizontal after installation.
rrectness of i
Connect compensator -4- to front handbrake cable -1-.
l purpos

Specified torques
nf
ercia
or
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m
atio
om

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Cop py
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rig ht
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by lksw
cted agen
Prote AG.
3.5 Adjusting parking brake

A new adjustment is only necessary when the handbrake cables,
brake carrier or brake shoes are renewed.
Procedure
Raising vehicle .

Amarok 2011
The foot brake must be functional and bled.

Brake shoes are set to basic dimension 294 mm after removal
and installation page 31 .
Front handbrake cable -1- is not allowed to hang down (no
slack in cable).
Release handbrake.
Firmly depress brake pedal three times.
Pull firmly on handbrake lever 5 times.
Adjust handbrake at adjustment nut -5- so that:
Brake rubs in first catch
Wheels can still just be turned by hand in second catch
Wheels can no longer be turned by hand in third catch
Release handbrake and check that both wheels turn freely. If
required turn adjustment nuts -5- back slightly.
Due to the automatic rear wheel brake adjustment there is no re
quirement to adjust the handbrake after making new/initial ad
justment.
lkswage es n
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t to the co
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mer
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or
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te
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o
pr
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fo
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Cop py
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by
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Prote AG.
3. Handbrake 39
Amarok 2011
4 Brake pedal
4.1 Assembly overview - brake pedal, page 40
4.2 Removing and installing brake pedal, page 41
4.1 Assembly overview - brake pedal

AG. Volkswagen AG d
agen oes
WARNING olksw not
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The brake pedal travel must ut not be restricted by additional floor
ho eo
ra
coverings. ss a c
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nl
pt
du
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itte
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Grease all bearing points with polycarbamide grease before in
erm
ab
stalling Electronic Parts Catalogue (ETKA) .
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wit
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Brake light switch - F- is located on brake master cylinder.
h re
hole
spec
es, in part or in w
1 - Pedal cluster/brake pedal
t to the co
page 41
rrectness of i
2 - Pin
l purpos
For plunger rod of brake

booster on brake pedal
nform
ercia
3 - Nut
m
Always renew after re

at
om
io
moving n
c
in t
or
For pedal cluster/brake

his
ate
pedal on plenum cham

do
priv
ber bulkhead
um
for
en
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25 Nm
n
t.
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Cop py
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4 - Nut
rig
gh ht
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Always renew after re
o
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moving Prote AG.
For pedal cluster/brake

pedal and brake booster
on plenum chamber
bulkhead
25 Nm
5 - Cap
6 - Securing spring
Secures pin
Item 2 (page 40)
7 - Yoke head/servo-assis
tance

Amarok 2011
4.2 Removing and installing brake pedal

Removing
If fitted, remove holder or clips for electrical cables from pedal
cluster. AG. Volkswagen n AG do
wage es
olks spring -1- from pin -2- for
Remove securing not yoke head/brake
yV gu
booster
ris
econnection
db on brake pedal. ara
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tho or
Pull
s a out pin -2-.
u ac
s
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e
Remove nuts -arrows A- and -arrows B-, total qty. 6, on both

nl
pt
du
sides of pedal mechanism.
an
itte
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erm
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ility
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Note
wit
, is n
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hole
spec
Nuts on left side are concealed by steering column.
es, in part or in w
t to the co
Remove pedal cluster/brake pedal -3-.
Installing
rrectness of i
l purpos
Fit new nuts -arrows A- and -arrows B- on both sides of pedal

cluster, and tighten them.
nf
ercia
Push pin -2- from right to left into yoke head/brake booster on orm
m
atio
brake pedal and push in securing spring -1-.

om
n in
or c
Specified torques
thi
te
sd
iva

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o
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t.
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Cop py
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rig ht
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by lksw
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Prote AG.
4. Brake pedal 41
Amarok 2011
47 Brakes - hydraulics
AG. Volkswagen AG d
agen oes
ksw
1 Front brake caliper ol not
V gu
d by ara
ise nte
or
1.1 Assembly overview - frontautbrake caliper, page 42
h eo
ra
ss c
1.2 Removing and installing brake caliper piston, page 43
ce
le
un
pt
an
d
1.1 Assembly overview - front brake caliper

itte
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ility
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Note
h re
hole
spec
When carrying out repairs, install all parts supplied in repair kit.
es, in part or in w
t to the co
Use only methylated spirits for cleaning the brake.
Apply thin coat of assembly paste to brake cylinder, piston and seal Electronic Parts Catalogue (ETKA) .
rrectness of i
l purpos
1 - Dust cap
nform
ercia
2 - Bleeder valve
m
Before screwing in, ap
a
com
tio
ply thin coat of assembly
n in
r
paste to thread Elec

te o
thi
tronic Parts Catalogue
s
iva
do
r
(ETKA) .
rp
cum
fo
en
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12 Nm
n
t.
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op py
3 - Brake hose
t. C rig
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Install without twisting
op Vo
by c lksw
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Specified torque when Prote AG.
being secured to brake

caliper: 14 Nm (pipe
with union nut).
Specified torque when
being secured to brake
caliper: 17 Nm (threa
ded pipe).
4 - Brake caliper housing
5 - Sealing ring
page 43
6 - Piston
page 43
7 - Protective cap
Take care not to dam
age when inserting pis
ton.
42 Rep. gr.47 - Brakes - hydraulics

Amarok 2011
1.2 Removing and installing brake caliper

piston
Removal wedge - 3409-
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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un
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ab
Piston resetting appliance - T10145-
ility
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wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
Removing
n
c
i
or
n thi
e
Press piston out of brake caliper housing using compressed

t
sd
va
air.
i
o
pr
cum
r
fo
en
ng
Place a piece of wood in the recess to prevent damage to the

t.
yi Co
pistons. ht. Cop py
rig
rig ht
py by
co Vo
by lksw
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Prote AG.
1. Front brake caliper 43

Amarok 2011
Remove seals using removal wedge - 3409- .

When removing ensure that the surface of the cylinder is not
damaged.
Note
Only use methylated spirits to clean brake caliper housing.
Installing
Apply a thin coat of assembly paste to pistons and seals before
inserting Electronic Parts Catalogue (ETKA) .
Insert oil seals in brake caliper housing.
Place protective cap with outer sealing lip on piston.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
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au ra
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ce
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nl
pt
du
an
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erm
ab
ility
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wit
, is n
h re
hole
spec
Using removal wedge - 3409- , insert inner sealing lip into cyl
es, in part or in w
t to the co
inder groove.
When doing this, hold piston in front of brake caliper housing.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
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Press piston into brake caliper housing using piston resetting

o
m
f
en
ng
tool - T10145- -1-.

t.
yi Co
Cop py
The outer sealing lip on the protective cap will then slip into the
t. rig
gh ht
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piston groove.
p by
co Vo
by lksw
cted agen
Prote AG.

Amarok 2011
2 Hydraulic system
2.1 General notes on brake fluid, page 45
2.2 Pre-bleeding hydraulic system, page 46
2.3 Bleeding hydraulic system following standard procedure,
page 48
2.4 Subsequent bleeding of hydraulic system, page 48
2.5 Testing for leaks, page 48
2.1 General notes on brake fluid

Brake fluid is hygroscopic, i.e. it has the tendency to absorb water
and moisture from the atmosphere
As the water content in the brake fluid rises, so its boiling point
falls. If the brake fluid gets very hot, this can lead to vapour bub
bles being formed, and failure of the brake.
The colour of the brake fluid becomes darker over the course of
time. A dark brake fluid colour is not an indication of its condition.
The discolouration is caused by chemical reactions.
WARNING
Rubber parts of brake system (sleeves, seals) are not com

patible with mineral oil, fuel and aggressive cleaning agents.
Even the smallest amounts on a seal or a sleeve will result in

changes to the parts. The consequences of a contaminated brake
system only become apparent months later, and then give rise to
greater expenses, particularly in vehicles equipped with ABS.AG. Volkswagen A
agen G do
es n
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ua
b
ed ran
oris tee
th or
au ac
ss
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nl
pt
du
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itte
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erm
ab
ility
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wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
2. Hydraulic system 45
Amarok 2011
-A- = Sleeve (original size)

-B- = Sleeve (swollen due to contact with mineral oil)
Summary of the above mentioned points:
Always keep brake fluid containers properly sealed. This is the
only way of preventing contamination by oil, dirt, cleaning agents
or moisture.
Carefully store brake fluid containers separately from oil (includ
ing hydraulic oil) and cleaning fluids. This is in order to avoid
confusion with other fluids or even filling a brake system with the
wrong product.
Caution
Brake fluid specification

AG. Volkswagen AG d
agen o
Volkswagen recommends using yV
olks new brake fluid in ac s not g
w e
cordance with VW Standard ed
b 501 14 in order to ensure ua
ran
ris
optimum function of thetho brake system. Alternatively, it is tee
or
possible to use a brake
ss
au
fluid that complies with the re ac
quirements of US Standard FMVSS 116 DOT 4 or
ce
le
un
DIN ISO 4925 CLASS 4. The specification is stated on the
pt
an
d
brake fluid packaging.

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ab
pe
Suitable brake fluids are available from a Volkswagen
ility
ot
partner.
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Note
Comply with the brake fluid change intervals as stated in the

rrectness of i
Maintenance Tables and the Service Schedule.

l purpos
Changing brake fluid

nform
ercia
Maintenance ; Booklet ; Descriptions of work; brake fluid:

m
changing
a
com
tion in
r
te o
2.2 Pre-bleeding hydraulic system

thi
s
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um
fo
en
ng
t.
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Brake filling and bleeding equipment - VAS 5234- or
Co
Cop py
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rig ht
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by lksw
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Prote AG.

Amarok 2011
Brake filling and bleeding equipment - V.A.G 1869-
Upgrade kit and extraction unit - V.A.G 1869/4-

Bleeding the brake system is described for brake filling and bleed
ing equipment - VAS 5234- and -V.A.G 1869- .
Note
Bleeding brake system on vehicles with ABS is performed in

same way as vehicles with a conventional brake system.
Only use new brake fluid conforming to US standard
FMVSS 116 DOT 4.
Genuine VW/Audi brake fluid conforms to this specification.
Brake fluid is poisonous. Also due to its corrosive effect brake
fluid must not come into contact with paintwork.
Brake fluid is hygroscopic, which means it absorbs moisture
from the ambient air and should therefore always be stored in
air-tight containers.
Rinse off spilled brake
swa
genfluid
AG. Vusing plentydoofeswater.
olkswagen AG
k not
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d by ara
A pre-pressure
oris of 2 bar is required for bleeding the hydraulic
e nte
eo unit.
th
u ra
Vehicles
ss with EDL, EDL/TCS or EDL/TCS/ESP:
a c
ce
e
nl
pt
du
an
itte
y li
Note
erm
ab
ility
ot p
If a chamber in brake fluid reservoir is completely empty (e.g.

wit
, is n
brake system leaking) in these vehicles, brake system must be

h re
hole
pre-bled first.
spec
es, in part or in w
t to the co
Connect brake filling and bleeding equipment - VAS 5234- or

-V.A.G 1869- .
rrectness of i
Bleeding sequence:
l purpos
1 - Bleed front left and front right brake calipers simultaneously.

2 - Bleed rear left and rear right wheel brake cylinders simulta
nform
ercia
neously.
m
at
Leave bleeder valves open with brake fluid hoses connected

om
io
until brake fluid free from air bubbles flows out.

n
c
in t
or
his
e
Hydraulic unit must then be bled again using function Basic

at
do
riv
setting of the Vehicle diagnostic tester.

p
cum
for
en
g
Initiate basic setting (to bleed brake system):

n
t.
yi Co
Cop py
.
Connect Vehicle diagnostic tester, and select function.
t rig
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co
Then bleed brake system as normal page 48 .
by lksw
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Prote AG.
Amarok 2011
2.3 Bleeding hydraulic system following

standard procedure
Adhere strictly to work sequence when bleeding brake system.
Connect brake filling and bleeding equipment - VAS 5234- or
-V.A.G 1869- .
Open bleeder valves in the specified order and bleed brake
calipers or wheel brake cylinders.
1 - Front left brake caliper
2 - Front right brake caliper
3 - Rear left wheel brake cylinder
4 - Rear right wheel brake cylinder
Use suitable bleeder hose. It must sit tightly on bleeder valve so
that no air can enter brake system.
Leave bleeder valve of a brake caliper or wheel brake cylinder
open until, with bleed hoses still fitted, brake fluid discharges
free of air bubbles.
2.4 Subsequent bleeding of hydraulic sys

tem
Carry out subsequent bleeding when:
brake pedal travel is too long or so-called soft brake pedal
Subsequent bleeding requires the assistance of a second me
chanic.
Connect brake filling and bleeding equipment - VAS 5234- .
Depress brake pedal firmly and hold.
Open bleeder valve on brake caliper.
wage
Fully depress brake pedal. olks es n
ot g
byV ua
ed ran
Close bleed valve with brake pedal hheld
oris down. tee
ut or
a ac
Release brake pedal slowly. ss
ce
e
nl
This bleed sequence must be carried out 5 times per brake caliper
pt
du
an
itte
or wheel brake cylinder.

y li
erm
ab
Bleeding sequence:
ility
ot p
wit
, is n
1 - Front left brake caliper

h re
hole
spec
2 - Front right brake caliper

es, in part or in w
t to the co
3 - Rear left wheel brake cylinder

4 - Rear right wheel brake cylinder
rrectness of i
A road test must be carried out after the brakes have been bled.
When doing this an ABS regulation must be performed at least
l purpos
once!
nform
2.5 Testing for leaks

mercia
at

om
ion
c
in t
r
Tester for brake pressure regulator - V.A.G 1310A-

o
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Amarok 2011
Adapter M10 - V.A.G 1310/6-
Check following components of brake system for leaks and that

they are functioning correctly:
Hydraulic unit
Brake hoses
Brake lines
Brake calipers or wheel brake cylinders
AG. Volkswagen A gen G do
swa es
Remove bleeder valveby
Voat
lk one of front brake calipers.
notConnect
gu
pressure gaugeri-V.A.G
se
d 1310 A- and bleed. ara
nt ee
tho o
Apply pressure au to brake pedal until gauge indicates a pressurer ac
ss
of 50 bar. The pressure must not drop by more than 4 bar
ce
e
nl
within the test period of 45 seconds. Renew brake master cyl

pt
du
an
inder if drop in pressure exceeds specification.

itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Amarok 2011
3 Brake booster and brake master cyl

inder
3.1 Assembly overview - brake booster/brake master cylinder,
page 50
3.2 Removing and installing brake booster, page 51
3.3 Removing and installing brake master cylinder,
page 53
3.4 Removing and installing brake light switch F , page 55
3.1 Assembly overview - brake booster/brake master cylinder

Complete brake master cylinders and brake boosters can be re
newed independently of each other.
Caution
Brake fluid specification
1 - Cap
2 - Brake fluid level warning
contact - F34-
3 - Brake fluid reservoir
4 - Connection
For supply hose to mas
ter cylinder
Only for vehicles with
manual gearbox olkswage es n
ot g
byV ua
5 - Vacuum hose ir se
d ran
tee
tho
or
6 - Sealing plug au ac
ss
ce
e
7 - Brake booster
nl
pt
du
an
itte
In petrol engines, nec

y li
erm
ab
essary vacuum is ob
ility
ot p
tained from intake mani

wit
fold and from vacuum

, is n
h re
pump.
hole
spec
Diesel engines are fitted

es, in part or in w
with a vacuum pump to

t to the co
generate the necessary

vacuum.
rrectness of i
Functional check:
l purpos
With engine switched

off, depress brake pedal
firmly several times (to
nf
ercia
exhaust vacuum in unit).

orm
m
atio
m
Now step on and hold

o
n in
c
brake pedal with medi

or
thi
e
um pressure and start

t
sd
iva
engine. If the brake

o
r
rp
cu
booster is functioning
o
m
f
en
ng
properly, the brake ped

t.
yi Co
op
al will be felt to go down C py
t. rig
as the servo takes effect.
gh ht
pyri by
Vo
co lksw
by
If faulty, renew complete (check all vacuum lines first). cted agen
Prote AG.

Amarok 2011
8 - Seal
For brake booster on plenum chamber bulkhead
9 - Nut
For brake booster and pedal cluster/brake pedal on plenum chamber bulkhead
25 Nm
10 - Sealing ring
11 - Brake master cylinder
Allocation Electronic Parts Catalogue (ETKA) .
Cannot be repaired. If faulty, renew as a complete unit.
12 - Brake light switch - F-
Including brake pedal switch -n AF47-
G. Vo.lkswagen AG d
wage oes
Removing and installing Volks page 55 not
g by ua
ed ran
13 - Bolt oris tee
th or
5 Nm au ac
ss
ce
le
14 - Brake line
un
pt
an
d
itte
From primary piston circuit of brake master cylinder to hydraulic unit.
y li
erm
ab
14 Nm
ility
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wit
is n
15 - Splash plate
h re
ole,
spec
16 - Nut
Always renew after removing t to the co
25 Nm
17 - Brake line
rrectne
From secondary piston circuit of brake master cylinder to hydraulic unit.

s
14 Nm
s o
cial p
f i
18 - Pin
nform
mer
Secures brake fluid reservoir on brake master cylinder

atio
m
Engage angle piece into retainer on brake fluid reservoir

o
n
c
i
or
n thi
e
19 - Sealing plug
t
sd
iva
o
r
Moisten with brake fluid and press into brake fluid reservoir.
p
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
3.2 Removing and installing brake booster
rig ht
py by
co Vo
by lksw
cted agen
Special tools and workshop equipment required Prote AG.
Brake filling and bleeding equipment - VAS 5234-
3. Brake booster and brake master cylinder 51

Amarok 2011
Removing
Vehicles with air conditioning system:
. Volkswagen AG
Pull connector -1- off refrigerant line -2-.kswagen AG does
not
Vol
y gu
Remove refrigerant line -2- from isplenum
ed b chamber bulkhead ara
nte
-arrow- and carefully tie up slightly
thor
higher. eo
au ra
s c
Continuation for all models: s
ce
e
nl
pt
du
Disconnect connector -3- from brake fluid level warning con
an
itte
y li
tact - F34- .
erm
ab
ility
ot p
Detach connector -4- from engine control unit.
wit
, is n
h re
Remove engine control unit -5- with bracket.
hole
spec
Unclip electrical connector -6- from wiring retainer and tie to
es, in part or in w
t to the co
one side.
Pull vacuum hose -7- out of brake booster.
rrectness of i
Lay out a sufficient number of lint-free cloths under brake
master cylinder.
l purpos
Draw off as much brake fluid as possible from brake fluid res
ervoir using brake filling and bleeding equipment - VAS 5234-
nf
ercia
or upgrade kit and extraction unit - V.A.G 1869/4- .

rm
m
atio
m
Vehicles with manual gearbox:

o
n in
or c
thi
e
Detach supply hose -1- for clutch master cylinder and seal.
t
sd
iva
o
r
rp
cu
Continuation for all models:

o
m
f
en
ng
t.
yi Co
Pull connector -3- off brake light switch - F- . t. Cop py
rig
gh ht
Unscrew brake lines -2- and -4- from brake master cylinder yri
p by
o Vo
and seal brake lines using sealing plugs from repair kit part
c by lksw
cted agen
number 1H0 698 311 A.
Prote AG.
Remove nuts -arrows- for brake master cylinder from brake

booster.
If installed, remove cover plate -5-.
Carefully take brake master cylinder -6- out of brake booster
together with brake fluid reservoir.

Amarok 2011
Remove securing spring -1- from pin -2- for yoke head/brake
booster connection on brake pedal.
Pull out pin -2-.
Remove nuts -arrows B-, total qty. 4, on both sides of pedal
mechanism/brake pedal.
Note
Nuts on left side are concealed by steering column.

Do not remove both top nuts -arrow A- (qty. 2) unless brake
booster jams in holes during removal and installation.
Carefully remove brake booster from the vehicle. If necessary,

push fuel lines and electrical cables slightly to one side.
Installing
Tighten new nuts -arrows B- and, if loosened beforehand, also

nut -arrow A- on both sides of pedal cluster.
Push pin -2- from right to left into yoke head/brake booster on
brake pedal and push in securing spring -1-.
After installation, brake system page 46 and clutch mecha
nism need to be bled Power transmission; Rep. gr. 30w;agen AG. Volkswagen AG doe
Bleeding clutch mechanism . yV
olks s no
t gu
b ara
ed
Specified torques thoris nte
e or
au ac
3.1 Assembly overview - brake booster/brake
ss master cyl
ce
inder, page 50
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
3.3 Removing and installing brake master
wit
, is n
h re
cylinder
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Amarok 2011 orise nte
h eo
Brake systems - Edition aut05.2013 ra
c
ss
ce
le
un
pt
an
d
itte
y li
rm
ab
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
ercia
Removing
m
a
Disconnect connector -3- from brake fluid level warning con
com
tio
tact - F34- .
n in
r
te o
thi
s
iva
do
r
rp
c
Note
um
fo
en
ng
t.
yi Co
The other items in the illustration are not relevant. Cop py
t. rig
gh ht
yri
Removing and installing brake master cylinder together with p by
o Vo
by c
brake fluid reservoir.
lksw
cted agen
Prote AG.
Lay out a sufficient number of lint-free cloths under brake

master cylinder.
Draw off as much brake fluid as possible from brake fluid res
ervoir using brake filling and bleeding equipment - VAS 5234-
or upgrade kit and extraction unit - V.A.G 1869/4- .
Vehicles with manual gearbox:
Detach supply hose -1- for clutch master cylinder and seal.
Continuation for all models:
Pull connector -3- off brake light switch - F- .
Unscrew brake lines -2- and -4- from brake master cylinder
and seal brake lines using sealing plugs from repair kit part
number 1H0 698 311 A.
Remove nuts -arrows- for brake master cylinder from brake
booster.
Remove heat shield (if installed) -5-.
Carefully take brake master cylinder -6- out of brake booster.
Installing
When assembling brake master cylinder with brake booster,
make sure plunger rod is properly positioned in brake master
cylinder.
After installation, brake system page 46 and clutch mecha
nism need to be bled Power transmission; Rep. gr. 30 ;
Bleeding clutch mechanism .
Specified torques
3.1 Assembly overview - brake booster/brake master cyl
inder, page 50

Amarok 2011
3.4 Removing and installing brake light

switch - F-
Removing
Pull connector -3- off brake light switch - F- .
Note
The other items in the illustration are not relevant.
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Remove bolt -1- from brake master cylinder.
rm
ab
pe
ility
Pull brake light switch - F- -2- off the brake master cylinder
ot
wit
underneath and out of the clip at the top -arrow-.
, is n
h re
hole
Installing
spec
es, in part or in w
t to the co
Tighten bolt -1-.
rrectness of i
Specified torques
l purpos
3.1 Assembly overview - brake booster/brake master cyl

inder, page 50
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Amarok 2011
4 Brake lines
4.1 Assembly overview - flanging tool, page 56
4.2 Required tools, page 57
4.3 Repairing brake lines, page 58
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4.1 Assembly overview - flanging btool w oes
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1 - Flanging tool upper part au ra
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ss
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Unbolt to change flang
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pt
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ing jaws .
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2 - Fastening for handle
ility
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Must be unbolted to gain
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access to securing bolt
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for upper part.
spec
es, in part or in w
3 - Securing bolt
t to the co
For flanging tool upper
part
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4 - Grub screws for flanging
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jaws
Centring and holding
flanging jaws .
nform
ercia
Hexagon socket head

m
at
bolt, 2 mm
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or
5 - Flanging jaws
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Assembly instructions
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Flanging jaw assembly instructions:

-VAS 6056/6- (dark) for black brake lines
-VAS 6056/7- (light) for green brake lines
Note
Arrow on rounded side of flanging jaws must point to edge of

housing. Straight side of flanging jaws must be installed to spin
dle, as flanging head is not otherwise formed correctly.

Amarok 2011
4.2 Required tools AG. Volkswagen AG d

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The flanging tool for brake lines - VAS 6056- can be used to flange by Vo gu
ara
brake lines with an outer pipe diameter of 5 mm without damaging
rise
d
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the coating. In certain cases, this allows sections of brake
autho
lines eo
ra
to be renewed at less expense. ss c
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nl
The use of flanging tool V.A.G. 1356 is not permitted due to the
pt
du
an
itte
coating and the diameter of the black brake lines.
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ility
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Note
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hole
spec
Brake pipes may only be bent up to max. 90. They otherwise
es, in part or in w
kink or reveal deformations which impermissibly constrict the
t to the co
pipe cross-section.
Preferably separate brake lines at underbody.
rrectness of i
The positions of the intermediate pieces must be selected so
l purpos
that they cannot chafe on moving parts.

Do not grease spindle; merely clean with methylated spirits.
nform
mercia
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Flanging tool for brake lines - VAS 6056-
or
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List of individual tools:
4. Brake lines 57
Amarok 2011
1 - Flanging tool - VAS 6056/1-

The flanging tool - VAS
6056/1- contains flang
ing jaws - VAS 6056/6- .
2 - Pipe cutter - VAS 6056/2-
Volkswagen AG
3 - Brake line scraper - VAS swagen AG. does
6056/3- yV
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Grub screws h(in ris shaft nte
t o adjus
and at side)auare
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ted and must
ss not be
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readjusted!
nl
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4 - Set of grips with plastic jaws
erm
ab
- VAS 6056/4-
ility
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5 - Pipe bending tool - VAS
, is n
h re
6056/5-
hole
spec
6 - Special wrench, 6 mm
es, in part or in w
t to the co
7 - Flanging jaws - VAS
6056/7-
rrectness of i
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nform
mercia
at
om
ion
c
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ate
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4.3 Repairing brake lines

Procedure
Unbolt relevant brake line at brake caliper or wheel brake cyl
inder; catch escaping brake fluid and dispose of this as per
regulations.
Cut through brake line at a suitable point (straight, freely ac
cessible section) with pipe cutter -2-.
Remove section to be renewed.
Degrease brake line surface.

Amarok 2011
Clamp brake line tightly in grip wrench -4- so that approx. 50

mm project from plastic jaws.
Clamp scraper -3- into a drill and position onto brake line.
Applying slight pressure against brake line, scrape coating off
brake line. Select a slow speed on the drill when doing this.
Note
Length of scraping is determined by stop in scraper.
Pull scraper off brake line and remove scrapings.
Remove set of grips and slide union bolt -D- onto brake line.
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Slide brake line -B- up to stop -A- in flanging tool.

ab
ility
ot p
wit
, is n
h re
Note
hole
spec
es, in part or in w
Brake line must be positioned against stop when the hexagon

t to the co
socket head bolts are tightened, or the flange will not be formed
correctly.
rrectness of i
Clamp brake line in flanging tool until brake line can no longer
l purpos
be moved. Then fold up stop -A- and use angled driver -C- to
tighten hexagon socket head bolts in diagonal sequence.
nf
ercia
orm
m
atio
Turn spindle as far as stop in flanging tool.

om
n in
c
Then turn spindle back again.

or
thi
te
sd
a
Unscrew hexagon socket head bolts in diagonal sequence.

iv
o
r
rp
cu
o
m
f
Remove brake line from flanging tool and clean it.

en
ng
t.
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op
Check brake line and flanging head.
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Briefly flush the section of brake line remaining in the vehicle:
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Connect brake filling and bleeding unit - VAS 5234- , connect
bleeder bottle hose to brake line flange and allow brake filling
and bleeding unit - VAS 5234- to run briefly until a little brake
fluid has run through.
Blow out new brake line to be inserted with compressed air.
4. Brake lines 59
Amarok 2011
Join brake lines using connector -E-.

Install brake line.
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a ac
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ility
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spec
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rrectness o
cial p
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Service

Service Department. Technical Information

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Copyright 2013 Volkswagen AG, Wolfsburg D4B80305DED

45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

4.2 Assembly overview - rear axle speed sensors G44 / G46 . . . . . . . . . . . . . . . . . . . . . . . . 15

1.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.1 Assembly overview - rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.3 Removing and installing brake shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.4 Resetting drum brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.5 Removing and installing wheel brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.5 Adjusting parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.3 Bleeding hydraulic system following standard procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 48

1.1 Technical data for brakes

Rear brake (drum brake)

1 Wheel brake mm 26.99

Brake lining, mm 6.7

Brake lining, mm 1.25

Brake master cylinder and brake booster

Brake master cylinder in mm 26.99

2.1 General information

2.2 Brake test

so controlled so that there is no difference in speed during the

The test rigs authorised by Volkswagen fulfil these requirements.

2 Rep. gr.00 - Technical data

45 Anti-lock brake system

1.1 General notes on ABS

Hydraulic pump -3- must not be separated from hydraulic unit.

1.2 Repair instructions for repair work on

Disconnect battery earth strap with ignition switched off.

Before carrying out welding work with an electric welding unit,

Place removed parts on a clean surface and cover.

seal open components.

During painting operations, the electronic control unit can be

4 Rep. gr.45 - Anti-lock brake system

2 Overview of fitting locations

2.1 Components and fitting locations - (ABS, EDL, ASR, ESP)

1 - Dash panel insert

Only on vehicles having y li

ing wheel and steering

Removing and installing

bulbs, switches - exteri

basic setting for steering

angle sender - G85-

5 - Rear axle shaft with wheel bearing/wheel bearing unit

The ABS sensor ring is installed on the rear axle shaft.

2. Overview of fitting locations 5

Yaw rate sender - G202- (only on vehicles having ESP).

6 Rep. gr.45 - Anti-lock brake system

3 Control unit and hydraulic unit

3.1 Assembly overview - control unit and hydraulic unit

should not be separated

from each other

draulic unit, always seal t to the co

Removing and installing

3. Control unit and hydraulic unit 7

8 - Connection for brake line

8 Rep. gr.45 - Anti-lock brake system

Sealing plug repair kit

Do not bend the brake

3. Control unit and hydraulic unit 9

Connect bleeder bot

sealing plug repair kit Electronic Parts Catalogue (ETKA) . an

Unlock connector from ABS control unit - J104- in ab