Servicio Sistemas de Frenos

Brake System from m.y. 1997 Brake System On Board Diagnostic (OBD) from m.y.
1997
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00 - General, Technical data

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45 - Anti-lock brake system

$%6 DQG $%6('/ %RVFK ABS system, general information Notes for repair work on ABS, ABS/EDL systems Hydraulic unit, assembly overview ABS hydraulic control unit, removing and installing $%6 DQG $%6('/ %RVFK ABS system, general information Notes for repair work on ABS systems Hydraulic unit, assembly overview ABS hydraulic control unit, removing and installing $%6('/$65(63 %RVFK ABS system, general information Notes for repair work on ABS systems Hydraulic unit, assembly overview ABS hydraulic control unit, removing and installing $%6 V\VWHP FRPSRQHQWV DW IURQW DQG UHDU D[OH UHPRYLQJ DQG LQVWDOOLQJ ABS front axle components, removing and installing ABS rear axle components, removing and installing (63 V\VWHP FRPSRQHQWV UHPRYLQJ DQG LQVWDOOLQJ Sender for Rotation Rate -G202- and Sensor for transverse acceleration -G200-, removing and installing ABS Control Module (w/EDL) -J104-, removing and installing Steering angle sensor -G85-, removing and installing
46 - Brakes - Mechanical components
)URQW EUDNHV VHUYLFLQJ Distinguishing characteristics of front brake calipers Front brakes, servicing (Lucas C54 fist caliper, 15" wheels) Brake pads, removing and installing Front brakes, servicing (Lucas RC 54 frame caliper, 15" wheels) Brake pads, removing and installing Front brakes, servicing (FN 3 fist caliper, 15" wheels) Brake pads, removing and installing Front brakes, servicing (FN 3 fist caliper, 16" wheels) Brake pads, removing and installing Front brakes, servicing (FNR fist caliper 16" wheels) Brake pads, removing and installing 5HDU EUDNHV VHUYLFLQJ ZKHHOV Brake pads, removing and installing Parking brake, adjusting 5HDU EUDNHV VHUYLFLQJ ZKHHOV Brake pads, removing and installing 3DUNLQJ EUDNH FDEOH UHPRYLQJ DQG LQVWDOOLQJ
Front parking brake cable, removing and installing Pull-lever, removing and installing Rear parking brake cable, removing and installing 3DUNLQJ EUDNH OHYHU UHPRYLQJ DQG LQVWDOOLQJ %UDNH SHGDO DVVHPEO\ RYHUYLHZ Brake pedal, removing and installing
47 - Brakes - Hydraulic components

)URQW EUDNH FDOLSHU VHUYLFLQJ Front brake caliper, servicing, (Lucas C54 fist caliper, 15" wheels) Front brake caliper pistons, removing and installing (Lucas C54 fist caliper, 15" wheels) Front brake caliper, servicing (Lucas RC 54 frame caliper 15" wheels) Front brake caliper pistons, removing and installing (Lucas RC 54 frame caliper, 15" wheels) Front brake caliper, servicing (FN3 fist caliper, 15" wheels) Front brake caliper pistons, removing and installing (FN 3 fist caliper, 15" wheels) Front brake caliper, servicing (FN3 fist caliper, 16" wheels) Front brake caliper pistons, removing and installing (FN 3 fist caliper, 16" wheels) Front brake caliper, servicing (FNR fist caliper, 16" wheels) Front brake caliper pistons, removing and installing (FNR fist caliper, 15" wheels) 5HDU EUDNH FDOLSHU VHUYLFLQJ Rear brake caliper piston, removing and installing Pressurized leak test %UDNH V\VWHP EOHHGLQJ YHKLFOHV ZLWK DQG ZLWKRXW $%6 Brake system, bleeding using US1116 brake bleeder Brake system, bleeding without brake filler and bleeder tool %UDNH ERRVWHU UHPRYLQJ DQG LQVWDOOLQJ Brake pressure regulator, adjusting %UDNHV FKHFNLQJ RQ G\QDPRPHWHU %UDNH ERRVWHUPDVWHU EUDNH F\OLQGHU DVVHPEO\ RYHUYLHZ Check-valve, checking 0DVWHU EUDNH F\OLQGHU UHPRYLQJ DQG LQVWDOOLQJ %UDNH ERRVWHU UHPRYLQJ DQG LQVWDOOLQJ *ORVVDU\

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Master brake cylinder Brake booster 1 2 3 Brake caliper Brake pad, thickness Brake disc Brake disc, thickness 4 Brake caliper, pistons
in mm in inches mm in mm mm in mm 9
23.81 4+8 4 13.5 282 18 54
Lucas C54
1) M-number (optional equipment no.), clarification Page 00-9

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Master brake cylinder Brake booster 1 2 3 Brake caliper Brake pad, thickness Brake disc
in mm in inches
23.81 9 4+ 8 4 Lucas RC54
mm in mm
13 280
Brake disc, thickness (internally vented) 4 Brake caliper, pistons
mm
24
in mm
54

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Master brake cylinder Brake booster 1 2 3 Brake caliper Brake pad, thickness Brake disc Brake disc, thickness (internally vented) 4 Brake caliper, pistons
in mm in inches mm in mm mm
25,4 9 4+ 8 4 FN 3 13.5 280 24
in mm
57


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Master brake cylinder Brake booster 1 2 3 Brake caliper Brake pad, thickness Brake disc Brake disc, thickness (internally vented) 4 Brake caliper, pistons
in mm in inches mm in mm mm
25,4 9 4+ 8 4 FN 3 13.5 300 26
in mm
57


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0QXPEHU 35 QR
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Master brake cylinder Brake booster 1 2 3 Brake caliper Brake pad, thickness Brake disc Brake disc,
in mm in inches mm in mm mm 9
25,4 4+8 4 FNR 14 313 26
thickness 4 Brake caliper, pistons in mm 57

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Master brake cylinder Brake booster 1 Brake disc Brake disc, thickness 2 3 Brake pad, thickness Brake caliper, pistons
in mm in inches in mm mm mm in mm
23.81 9 4+8 4 280 12 11.5 38


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0QXPEHU 35 QR
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in mm in inches in mm mm mm in mm 9
25,4 4+8 4 280 12 11.5 38


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in mm in inches in mm mm mm in mm 9
25.4 4+8 4 280 12 11.5 38
clarification
Page 00-9

'HWHUPLQLQJ EUDNH FDOLSHU DOORFDWLRQ YLD 0 QXPEHU 35 QR Depending on the brake caliper version, there is a different PR no. entered on the vehicle data plate. ,QVWDOODWLRQ SRVLWLRQ RI WKH YHKLFOH GDWD SODWH DUURZ Left Hand Drive (LHD) vehicles - left A-pillar, next to central electronics
3ODFHPHQW RI 0QXPEHU 35 QR RQ YHKLFOH GDWD SODWH DUURZ 1LU = 15" fist caliper FN3 1LP = 15" Lucas fist caliper C54 1LE = 15" Lucas frame caliper RC 54 1LB = 16" fist caliper FN3 1LB = 16" fist caliper FNR 1RWH 7KH EUDNH FDOLSHU DEEUHYLDWLRQ FDQ EH ORFDWHG HOVHZKHUH RQ WKH YHKLFOH GDWD SODWH GHSHQGLQJ RQ WKH DPRXQW RI HTXLSPHQW LQVWDOOHG

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The ABS brake system is divided diagonally (two circuits). The vacuum brake servo unit boosts the brakes pneumatically. The hydraulic unit and control module are one unit and must always be replaced and installed together. &RQQHFWLRQ RI EUDNH OLQHV IURP WDQGHP PDVWHU EUDNH F\OLQGHU WR K\GUDXOLF XQLW 1 - Primary piston circuit 2 - Hydraulic control unit to rear right brake caliper 3 - Hydraulic control unit to front left brake caliper 4 - Secondary piston circuit 5 - Hydraulic control unit to rear left brake caliper 6 - Hydraulic control unit to front right brake caliper

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%UDNH OLQH Master brake cylinder/primary piston circuit to hydraulic control unit %UDNH OLQH Hydraulic control unit to front left brake caliper %UDNH OLQH Hydraulic control unit to rear left brake caliper %UDNH OLQH Hydraulic control unit to rear right brake caliper %UDNH OLQH Hydraulic control unit to front right brake caliper $%6('/ K\GUDXOLF FRQWURO PRGXOH bolted to control module The hydraulic control module must be replaced completely if malfunctioning

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6SHFLDO 7RROV DQG (TXLSPHQW VAG1331 torque wrench
VAG1869/2 brake pedal depressor

Installation location: The control module is bolted to the hydraulic unit and is located at left in the engine compartment. :$51,1* 'R QRW EHQG EUDNH OLQHV QHDU WKH K\GUDXOLF XQLW 5HPRYLQJ - Note radio code (for vehicles equipped with coded anti-theft radio). - Disconnect Ground (GND) strap from battery - Disconnect connector from control module. - Draw as much brake fluid as possible from brake fluid reservoir using a bleeder bottle. - Insert VAG1869/2 brake pedal depressor. - Operate brake pedal using brake pedal depressor. - Attach bleeder hose of bleeder bottle to left-front brake caliper bleeder screw and open bleeder screw. - Close front left bleeder screw.

- Remove Ground (GND) wire from hydraulic unit. - Place a sufficient number of lint-free cloths under control module and hydraulic unit. - Unscrew brake lines at hydraulic unit. Seal brake lines and threaded holes using plugs. - Remove hydraulic unit with control module. ,QVWDOOLQJ 1RWHV 'R QRW UHPRYH VHDOLQJ SOXJV DW K\GUDXOLF XQLW XQWLO WKH FRUUHVSRQGLQJ EUDNH OLQH LV DERXW WR EH LQVWDOOHG ,I WKH VHDOLQJ SOXJV DUH UHPRYHG WRR HDUO\ EUDNH IOXLG FDQ HVFDSH ,I WKLV RFFXUV XQLW PD\ QRW EH VXIILFLHQWO\ ILOOHG RU DGHTXDWHO\ EOHG - Rest of installation is the reverse of removal. - Bleed brake system Page 47-33 .

7LJKWHQLQJ WRUTXHV Brake lines to ABS aggregate: Thread M 10 x 1 Thread M 12 x 1 15 Nm 15 Nm

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ABS allocation in Left Hand Drive (LHD) vehicles. The ABS brake system is divided diagonally (two circuits). The vacuum brake servo unit boosts the brakes pneumatically. The hydraulic unit and control module are one unit and must always be replaced and installed together.
ABS disturbances affect the brake system and the booster. Account for differences in braking behavior. When the ABS warning lamp is lit up, the rear wheels may lock prematurely during braking!

Hydraulic unit -a- and control module -b- are one unit and must always be replaced together if malfunctioning. New control modules that are delivered as a replacement part are coded.
&RQQHFWLRQ RI EUDNH OLQHV IURP WDQGHP PDVWHU EUDNH F\OLQGHU WR K\GUDXOLF XQLW A - Secondary piston circuit B - Primary piston circuit 1 - Hydraulic control unit to rear left brake caliper 2 - Hydraulic control unit to rear right brake caliper
3 - Hydraulic control unit to front right brake caliper 4 - Hydraulic control unit to front left brake caliper

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%UDNH OLQH Master brake cylinder/primary piston circuit to hydraulic control unit %UDNH OLQH Hydraulic control unit to front right brake caliper %UDNH OLQH Hydraulic control unit to rear right brake caliper %UDNH OLQH Hydraulic control unit to rear left brake caliper %UDNH OLQH Hydraulic control unit to front left brake caliper +H[QXW WLJKWHQ WR 1P 3URWHFWLYH FDS

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6SHFLDO 7RROV DQG (TXLSPHQW VAG1331 torque wrench

Installation location: The control module is bolted to the hydraulic unit and is located at left in the engine compartment. :$51,1* 'R QRW EHQG EUDNH OLQHV QHDU WKH K\GUDXOLF XQLW 5HPRYLQJ - For vehicles equipped with coded anti-theft radio, note radio code, obtain if necessary. - Disconnect Ground (GND) strap from battery - Disengage connector from control module (arrow -1-) and disconnect (arrow -2-). - Draw as much brake fluid as possible from brake fluid reservoir using a bleeder bottle. - Insert VAG1869/2 brake pedal depressor. - Operate brake pedal using brake pedal depressor. - Attach bleeder hose of bleeder bottle to left-front brake caliper bleeder screw and open bleeder screw.

- Close front left bleeder screw. - Place a sufficient number of lint-free cloths under control module and hydraulic unit. - Unscrew brake lines at hydraulic unit. Seal brake lines and threaded holes using plugs. - Remove hydraulic unit with control module. ,QVWDOOLQJ 1RWHV 'R QRW UHPRYH VHDOLQJ SOXJV DW K\GUDXOLF XQLW XQWLO WKH FRUUHVSRQGLQJ EUDNH OLQH LV DERXW WR EH LQVWDOOHG ,I WKH VHDOLQJ SOXJV DUH UHPRYHG WRR HDUO\ EUDNH IOXLG FDQ HVFDSH ,I WKLV RFFXUV XQLW PD\ QRW EH VXIILFLHQWO\ ILOOHG RU DGHTXDWHO\ EOHG - Rest of installation is the reverse of removal. - Bleed brake system Page 47-33 .


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ABS allocation in Left Hand Drive (LHD) vehicles. The ABS brake system is divided diagonally (two circuits). The vacuum brake servo unit boosts the brakes pneumatically. 9HKLFOHV ZLWK $%6('/$65 The hydraulic unit and control module are one unit and must always be replaced and installed together. 9HKLFOHV ZLWK $%6('/$65(63 Hydraulic unit and control module are allocated separately in vehicle and may be removed and installed independently from each other.
ABS disturbances affect the brake system and the booster. Account for differences in braking behavior. When the ABS warning lamp is lit up, the rear wheels may lock prematurely during braking!

Hydraulic unit -a- and control module -b- are one unit and must always be replaced together if malfunctioning. New control modules that are delivered as a replacement part are coded.
&KDUDFWHULVWLFV 123Hydraulic unit ABS return flow pump Hydraulic pump for traction control with brake pressure sensor

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1RWHV 7KH K\GUDXOLF XQLW LV LQVWDOOHG DW IURQW OHIW LQ WKH HQJLQH FRPSDUWPHQW :KHQ UHPRYLQJ DQG LQVWDOOLQJ EUDNH OLQHV EH VXUH WR PDUN DQG LQVWDOO OLQHV UHODWLYH WR LQGLFDWLRQV RQ K\GUDXOLF XQLW %UDNH OLQHV PXVW QRW EH PL[HG XS ZKHQ FRQQHFWLQJ FKHFNLQJ 7DQGHP EUDNH ERRVWHU On gasoline engines vacuum is supplied from intake manifold. On diesel engines, a vacuum pump is installed for vacuum creation.

Function test - With engine switched off, depress brake pedal firmly several times (to deplete vacuum in tool). - Depress and hold brake pedal with average foot pressure and start engine. If brake booster is working properly, pedal will be felt to give noticeably under foot (booster assistance becomes effective). If malfunctioning: replace as complete unit only. Check-valve (in vacuum hose) Page 47-55 Function test Page 47-55 Removing and installing Page 47-59 %UDNH IOXLG UHVHUYRLU 7DQGHP PDVWHU EUDNH F\OLQGHU

%UDNH OLQH Master brake cylinder/secondary piston circuit to hydraulic unit Identification at hydraulic unit HZ2 %UDNH OLQH Hydraulic control unit to front left brake caliper Identification at hydraulic unit VL %UDNH OLQH Hydraulic control unit to front right brake caliper Identification at hydraulic unit VR +H[QXW WLJKWHQ WR 1P 3URWHFWLYH FDS +H[QXW WLJKWHQ WR 1P %ROW 1P &RQVROH

$%6 K\GUDXOLF XQLW bolted to control module The hydraulic control module must be replaced completely if malfunctioning %UDNH OLQH Hydraulic control unit to rear left brake caliper Identification at hydraulic unit HL %UDNH OLQH Hydraulic control unit to rear right brake caliper Identification at hydraulic unit HR %UDNH OLQH Hydraulic unit to hydraulic pump for traction control Identification at hydraulic unit VLPIdentification at hydraulic pump for traction control -HE
+\GUDXOLF SXPS IRU WUDFWLRQ FRQWURO &RQQHFWLRQ IRU EUDNH IOXLG IURP EUDNH IOXLG UHVHUYRLU %UDNH SUHVVXUH VHQVRU For malfunctions, always replace together with the hydraulic pump for traction control Identification at hydraulic pump for traction control -BA +DUQHVV FRQQHFWRU IRU K\GUDXOLF SXPS IRU WUDFWLRQ FRQWURO %UDNH OLQH Master brake cylinder/secondary piston circuit to hydraulic pump for traction control Identification at hydraulic pump for traction control -HZ

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VAG1331 torque wrench

Installation location: The control module is bolted to the hydraulic unit and is located at left in the engine compartment. :$51,1* 'R QRW EHQG EUDNH OLQHV QHDU WKH K\GUDXOLF XQLW 5HPRYLQJ - For vehicles equipped with coded anti-theft radio, note radio code, obtain if necessary. - Disconnect Ground (GND) strap from battery
- Disengage connector from control module (arrow -1-) and disconnect (arrow -2-). - Draw as much brake fluid as possible from brake fluid reservoir using a bleeder bottle. - Insert VAG1869/2 brake pedal depressor. - Operate brake pedal using brake pedal depressor. - Attach bleeder hose of bleeder bottle to left-front brake caliper bleeder screw and open bleeder screw.

- Close front left bleeder screw. - Place a sufficient number of lint-free cloths under control module and hydraulic unit. - Unscrew brake lines at hydraulic unit and hydraulic pump for traction control. Seal brake lines and threaded holes using plugs. - Remove hydraulic unit with control module and hydraulic pump for traction control. ,QVWDOOLQJ 1RWHV 'R QRW UHPRYH VHDOLQJ SOXJV DW K\GUDXOLF XQLW XQWLO WKH FRUUHVSRQGLQJ EUDNH OLQH LV DERXW WR EH LQVWDOOHG ,I WKH VHDOLQJ SOXJV DUH UHPRYHG WRR HDUO\ EUDNH IOXLG FDQ HVFDSH ,I WKLV RFFXUV XQLW PD\ QRW EH VXIILFLHQWO\ ILOOHG RU DGHTXDWHO\ EOHG - Rest of installation is the reverse of removal.
- Bleed brake system
Page 47-33 .


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5LJKW DQG OHIW IURQW $%6 ZKHHO VSHHG VHQVRUV * * Before inserting sensor, clean inner surface of bore hole and coat with securing grease G 000 650 Note assembly sequence: Install sensor next and then wire; starting at sensor, install in appropriate brackets along with rubber grommets Wire routing Fig. 1 %UDFNHW For 16" wheels, a different bracket is installed Fig. 2 :KHHO EHDULQJ KRXVLQJ 'ULYH D[OH With rotor for speed sensor

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5HPRYLQJ DQG LQVWDOOLQJ $%6 ZKHHO VSHHG VHQVRU DW IURQW D[OH 5HPRYLQJ - Raise vehicle. - Remove bolt -1- from wheel speed sensor. - Pull ABS wheel speed sensor out of wheel bearing housing. - Unclip wire -2- from bracket (arrow). - Disconnect harness connector -3- for wheel speed sensor wire. ,QVWDOOLQJ
- Connect harness connector -3- for wheel speed sensor wire. The two tabs at the connectors for harness connector -3- must align with each other. - Clip wire -2- into bracket (arrow).

- Before inserting wheel speed sensor, clean inner surface of bore hole and coat sensor completely with securing grease G 000 650 - Insert wheel speed sensor in hole of wheel bearing housing and tighten bolt Page 4536 . - Turn wheels completely to left and right stop positions and check clearance to ABS wheel speed sensor wiring. &KHFNLQJ UHPRYLQJ DQG LQVWDOOLQJ URWRU DW IURQW D[OH - Raise vehicle. - Check rotor for dirt and damage by rotating drive axle. - If rotor is damaged, drive axle must be removed together with rotor and the outer constant velocity joint must be replaced.
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&RQWURO DUP %UDFNHW When installing, hook into control arm first 5LYHW 6RFNHW KHDG EROW 1P $%6 ZKHHO VSHHG VHQVRU Before inserting sensor, clean inner surface of bore hole and coat with securing grease G 000 650 Note assembly sequence: Install sensor next and then wire; starting at sensor, install in appropriate brackets along with rubber grommets

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5HPRYLQJ DQG LQVWDOOLQJ $%6 ZKHHO VSHHG VHQVRU DW UHDU D[OH 5HPRYLQJ - Raise vehicle. - For vehicles with brake pad wear indicator, additionally rotate harness connector for brake pad wear indicator by 90 and remove from cable channel to side. - Disconnect harness connector for brake pad wear indicator.
- Remove bolt from wheel speed sensor. - Remove wheel speed sensor from control arm. - Unclip wire (arrow -A- and -B-) from bracket at control arm.

- Disconnect harness connectors -1- and -2-. - Unclip wire from bracket -3- in direction of arrow. ,QVWDOOLQJ - Before inserting wheel speed sensor, clean inner surface of bore hole and coat sensor completely with securing grease G 000 650 - Insert wheel speed sensor in hole of control arm and tighten bolt Page 45-41 Rest of installation is the reverse of removal.

&KHFNLQJ UHPRYLQJ DQG LQVWDOOLQJ URWRU DW UHDU D[OH )URQW :KHHO 'ULYH ):' - Raise vehicle. - Check rotor for dirt and damage.
- If rotor is damaged, tension disc must be removed and replaced.
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A description of the construction and function of the ESP system is included in self study program no. 204.
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5HPRYLQJ - For vehicles equipped with coded anti-theft radio, note radio code, obtain if necessary. - Disconnect battery. - Remove passenger-side storage compartment.
5HSDLU 0DQXDO %RG\ ,QWHULRU 5HSDLU *URXS ,QVWUXPHQW SDQHO ,QVWUXPHQW FOXVWHU UHPRYLQJ DQG LQVWDOOLQJ - Pull back the front right foot carpet far enough that the Sender for Rotation Rate -G202- and the Sensor for transverse acceleration -G200are accessible.

Installation location: The Sender for Rotation Rate -G202- and the Sensor for transverse acceleration -G200- are secured on the wheel housing, inside at the A-pillar. - Disconnect connector from Sender for Rotation Rate -G202- and Sensor for transverse acceleration -G200-. - Unscrew nuts and remove Sender for Rotation Rate -G202- and Sensor for transverse acceleration -G200-. ,QVWDOOLQJ :$51,1* :KHQ UHSODFLQJ 6HQGHU IRU 5RWDWLRQ 5DWH * DQG 6HQVRU IRU WUDQVYHUVH DFFHOHUDWLRQ * PDNH VXUH WKDW WKH ZKHHO KRXVLQJ LV QRW GDPDJHG RU GHIRUPHG DFFLGHQW LQ WKH DUHD RI WKH VHQVRU $OLJQPHQW RI WKH VHQVRU LV HVVHQWLDO IRU WKH
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5HPRYLQJ - For vehicles equipped with coded anti-theft radio, note radio code, obtain if necessary. - Disconnect battery. - Remove passenger-side storage compartment.
5HSDLU 0DQXDO %RG\ ,QWHULRU 5HSDLU *URXS ,QVWUXPHQW SDQHO ,QVWUXPHQW FOXVWHU UHPRYLQJ DQG LQVWDOOLQJ Location: ABS Control Module (w/EDL) -J104- is located behind instrument panel on passengerside, right next to center console. - Fold foam matting forward. - Disconnect connector from ABS Control Module (w/EDL) -J104-, move lever -1- in direction of arrow to do so. 2 - Center console - Remove control module -3-.

,QVWDOOLQJ - Installation is the reverse of removal. - Code radio. - Code control module.
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- Put wheels in straight-ahead position. - Remove airbag unit and steering wheel.
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- Remove trim above steering column switch. - Disconnect connectors (arrows).
- Carefully lift hooks (arrows A) and remove steering angle sensor -G85-. Arrow B points to the hole for the center position marking. This marking is required for installation.

,QVWDOOLQJ 6WHHULQJ DQJOH VHQVRU * PXVW EH LQ FHQWHU SRVLWLRQ EHIRUH LQVWDOODWLRQ - Position the steering angle sensor -G85- until tabs (arrows A) engage. - A yellow dot must be visible in the hole (arrow -1) %H VXUH WKDW FHQWHU SRVLWLRQ LV PDLQWDLQHG Rest of installation is the reverse of removal. - Install airbag unit and steering wheel.
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/XFDV ILVW FDOLSHU & 0QXPEHU /3 3DJH Characteristics: Symmetrical vibration dampener -AVW symbol -B- behind protrusion -CContinuous strengthening ribs -DAdditional technical data Page 00-1
/XFDV IUDPH FDOLSHU 5& 0QXPEHU /( 3DJH Characteristics: Closed frame -ABrake pads visible from above Additional technical data Page 00-1

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Engage retaining spring -A- in brake caliper housing. Additional technical data Page 00-1
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Engage two-part retaining spring -A- with additional dampening sheet in brake caliper housing. With brake pad wear indicator -B16" is engraved on brake caliper -CAdditional technical data Page 00-1

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%UDNH FDUULHU %UDNH SDGV Pads on both sides of axle must always be replaced together. Brake pad thickness: 13.5 mm Checking thickness 5HSDLU 0DQXDO 0DLQWHQDQFH Wear limit: 2 mm without brake pad mounting plate (remaining pad thickness) Removing and installing Page 46-7 3URWHFWLYH FDS *XLGH SLQV 6HOIORFNLQJ EROW 1P Always replace %UDNH FDOLSHU Servicing 47-1 Page
Distinguishing characteristics Page 46-1

6RFNHW KHDG EROW 1P %UDNH GLVF Pads on both sides of axle must always be replaced together. Remove brake caliper before removing Unventilated brake disc: 282 mm Brake disc thickness: 18 mm Wear limit: 15 mm +H[ EROW 1P %DFNLQJ SODWH %UDNH OLQH ZLWK FRQQHFWLRQ QLSSOH +H[ EROW 1P %UDFNHW %UDNH KRVH

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5HPRYLQJ - Remove wheels. - Unscrew lower mounting bolt for brake caliper housing. Counterhold at guide pin.
- Swing brake caliper housing upward. - Remove brake pads. ,QVWDOOLQJ 1RWH 3UHVV SLVWRQ EDFN LQWR FDOLSHU KRXVLQJ XVLQJ UHVHWWLQJ WRRO EHIRUH LQVHUWLQJ QHZ EUDNH SDGV %HIRUH SXVKLQJ EDFN WKH SLVWRQ VLSKRQ VRPH RI WKH EUDNH IOXLG RXW RI WKH EUDNH IOXLG UHVHUYRLU 2WKHUZLVH HVSHFLDOO\ LI UHVHUYRLU KDV EHHQ WRSSHG RII IOXLG ZLOO RYHUIORZ DQG FDXVH GDPDJH - Press piston back. - Insert brake pads.

- Swing brake caliper housing downward and tighten mounting bolts to correct tightening torque. 1RWHV 5HSDLU NLW LQFOXGHV WZR VHOIORFNLQJ KH[EROWV ZKLFK PXVW DOZD\V EH LQVWDOOHG $IWHU UHSODFLQJ EUDNH SDGV DQG EHIRUH PRYLQJ YHKLFOH GHSUHVV EUDNH SHGDO VHYHUDO WLPHV ILUPO\ WR SURSHUO\ VHDW EUDNH SDGV LQ WKHLU QRUPDO RSHUDWLQJ SRVLWLRQ

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%ULGJH Bolt to brake caliper housing Fig. 1 %UDNH GLVF Pads on both sides of axle must always be replaced together. To remove, first remove lower bolt of brake carrier and loosen upper bolt Internally ventilated brake disc: 280 mm Brake disc thickness: 24 mm Wear limit: 20 mm 6RFNHW KHDG EROW 1P

2XWHU EUDNH SDG With adhesive foil on brake pad mounting plate Pads on both sides of axle must always be replaced together. Removing and installing Page 46-15 Brake pad thickness: 13 mm Checking thickness 5HSDLU 0DQXDO 0DLQWHQDQFH Wear limit: 2 mm without brake pad mounting plate (remaining pad thickness) ,QQHU EUDNH SDG Pads on both sides of axle must always be replaced together. Removing and installing Page 46-15 Brake pad thickness: 13 mm Checking thickness 5HSDLU 0DQXDO 0DLQWHQDQFH
Wear limit: 2 mm without brake pad mounting plate (remaining pad thickness)

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Bolt to bridge Fig. 1 Distinguishing characteristics Page 46-1

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- Position bridge using socket-head bolts and tighten. - Insert sheet -1- (50 x 24 x 2 mm selfprepared) between surface of brake disc and underside of bridge. This ensures sufficient clearance between bridge and brake disc. - Press brake caliper housing/bridge against sheet and tighten hex nuts of guide pins. - Remove sheets and check clearance of brake disc.
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5HPRYLQJ - Remove wheels. - Remove securing spring. - Drive out brake pad retaining pins using drift -a-. - Remove inner brake pad. - Shift frame. - Loosen outer brake pad from brake pad mounting surface at bridge using a screwdriver or something similar. - Press piston back. ,QVWDOOLQJ 1RWH 3UHVV SLVWRQ EDFN LQWR FDOLSHU KRXVLQJ XVLQJ UHVHWWLQJ WRRO EHIRUH LQVHUWLQJ QHZ EUDNH SDGV %HIRUH SXVKLQJ EDFN WKH SLVWRQ VLSKRQ VRPH RI WKH EUDNH IOXLG RXW RI WKH EUDNH IOXLG UHVHUYRLU 2WKHUZLVH HVSHFLDOO\ LI UHVHUYRLU KDV EHHQ WRSSHG RII IOXLG ZLOO RYHUIORZ DQG FDXVH GDPDJH

- Clean brake caliper housing, especially the adhesive surface for the brake pad, it must be free of residual adhesive and grease.
- Install inner brake pad. - Install pad retaining pins enough that inner pad is held on. - Remove protective foil from outer brake pad. - Carefully insert outer brake pads. - Press brake pad retaining pins completely through and install securing spring. 1RWHV :KHQ LQVHUWLQJ RXWHU EUDNH SDG EH VXUH WKDW LW GRHV QRW DGKHUH WR EUDNH FDOLSHU KRXVLQJ SULRU WR DFKLHYLQJ FRUUHFW LQVWDOODWLRQ SRVLWLRQ 'R QRW GDPDJH DGKHVLYH VXUIDFHV $IWHU LQVWDOOLQJ QHZ EUDNH SDGV RSHUDWH EUDNH SHGDO SRZHUIXOO\ WZR RU WKUHH WLPHV DQG KROG SHGDO IRU WR VHFRQGV VR WKDW RXWHU SDGV DGKHUH VHFXUHO\ WR EUDNH FDOLSHU KRXVLQJ 7KLV KHOSV HQVXUH D UHOLDEOH DGKHVLRQ RI WKH RXWHU SDG DQG QRLVHIUHH EUDNLQJ

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%UDNH GLVF Brake disc thickness: 24 mm Wear limit: 20 mm Always replace pads on both sides of axle if worn. Do not separate brake discs from wheel hub with force or rust solvent, otherwise brake discs will be damaged. +H[ EROW Always replace after disassembly 5HSDLU 0DQXDO 6XVSHQVLRQ :KHHOV 6WHHULQJ IURP P\ 5HSDLU *URXS 'ULYH D[OHV VHUYLFLQJ :KHHO EROW Modified wheel bolt 5HSDLU 0DQXDO 6XVSHQVLRQ :KHHOV 6WHHULQJ IURP P\ 5HSDLU *URXS 7LJKWHQLQJ WRUTXHV IRU ZKHHO EROWV

%UDNH SDGV Brake pad thickness: 13.5 mm Brake pad with retaining spring sits at piston Brake pad with adhesive foil on mounting plate sits on outside Wear limit: 2 mm without brake pad mounting plate (remaining pad thickness) Checking thickness 5HSDLU 0DQXDO 0DLQWHQDQFH Pads on both sides of axle must always be replaced together. 5HWDLQLQJ VSULQJ Insert in both holes of brake caliper housing

%UDNH FDUULHU Supplied as preassembled replacement part with sufficient grease on guide pins Use repair kit when protective caps are damaged. Use grease packet supplied to lubricate guide pins %UDNH FDOLSHU Removing and installing Page 46-22 *XLGH SLQV 1P IW OE Removing and installing Page 46-22 &RQFHDOPHQW FDS %UDNH OLQH ZLWK FRQQHFWLRQ QLSSOH +H[ EROW 1P

%UDFNHW %UDNH KRVH 'ULYH D[OH With rotor for speed sensor +H[ EROW 1P :KHHO EHDULQJ KRXVLQJ %UDFNHW $%6 ZKHHO VSHHG VHQVRU Before inserting sensor, clean inner surface of bore hole and coat with securing grease G 000 650 6RFNHW KHDG EROW 1P +H[ EROW %DFNLQJ SODWH +H[ EROW 1P


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- Remove protective caps (arrows).
- Disengage brake pad retaining spring from brake caliper housing and remove. 1RWH 7LOW UHWDLQLQJ VSULQJ RXW RI D KROH LQ WKH KRXVLQJ E\ SUHVVLQJ LQ GLUHFWLRQ RI DUURZ DUURZ LV PDUNHG RQ UHWDLQLQJ VSULQJ DQG UHPRYH

- Remove both guide pins from brake caliper. - Remove brake caliper housing and set aside so that the weight of the brake caliper does not burden or damage the brake hose. - Remove brake pads from brake caliper housing or from brake carrier.
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WRSSHG RII IOXLG ZLOO RYHUIORZ DQG FDXVH GDPDJH - Press piston back.

- Insert brake pad with retaining spring in brake caliper housing. - Install outer brake pad on brake carrier. - Tighten brake caliper housing to brake carrier using both guide pins (25 Nm). - Install both protective caps. - Place one bow of the retaining spring under the brake carrier and insert a tab into hole in housing (arrow A).Tension second bow under the brake carrier and engage second tab in hole (arrow B). 1RWHV :KHQ LQVHUWLQJ RXWHU EUDNH SDG EH VXUH WKDW LW GRHV QRW DGKHUH WR EUDNH FDOLSHU KRXVLQJ SULRU WR DFKLHYLQJ FRUUHFW LQVWDOODWLRQ SRVLWLRQ 'R QRW GDPDJH DGKHVLYH VXUIDFHV
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6RFNHWKHDG EROW 1P %UDNH GLVF Brake disc thickness: 26 mm Wear limit: 22 mm Always replace pads on both sides of axle if worn. Do not separate brake discs from wheel hub with force or rust solvent, otherwise brake discs will be damaged. %UDNH SDGV Pads on both sides of axle must always be replaced together. With wear indicator - When the appropriate wear limit has been reached (limit: 2 to 3 mm), the warning lamp lights up Brake pad thickness: 13.5 mm Checking thickness
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Wear limit: 8 mm (including brake pad mounting plate) Removing and installing Page 4630 Brake pad with retaining spring sits at piston Brake pad with adhesive foil on backing plate sits on outside +DUQHVV FRQQHFWRU For pad replacement, remove from bracket, -item no. 12 5HWDLQLQJ VSULQJ with additional dampening sheet Insert in both holes of brake caliper housing %UDNH FDUULHU Supplied as preassembled replacement part with sufficient grease on guide pins Use repair kit when protective
caps are damaged. Use grease packet supplied to lubricate guide pins

%UDNH FDOLSHU Removing and installing Page 46-30 *XLGH SLQV 1P IW OE Removing and installing Page 46-30 &RQFHDOPHQW FDS %UDNH OLQH ZLWK FRQQHFWLRQ QLSSOH %UDFNHW %UDNH KRVH +H[ EROW 1P +H[ EROW 1P 'ULYH D[OH ZLWK $%6 ZKHHO VSHHG VHQVRU URWRU :KHHO EHDULQJ KRXVLQJ

$%6 ZKHHO VSHHG VHQVRU Before inserting sensor, clean inner surface of bore hole and coat with securing grease G 000 650 %UDFNHW 6RFNHW KHDG EROW 1P %DFNLQJ SODWH +H[ EROW 1P


5HPRYLQJ 1RWH :KHQ UHPRYLQJ PDUN EUDNH SDGV WKDW ZLOO EH XVHG DJDLQ ,QVWDOO LQ WKH VDPH SRVLWLRQ RWKHUZLVH EUDNLQJ HIIHFW ZLOO EH XQHYHQ - Remove wheels.
- Remove protective caps (arrows).
- Disengage brake pad retaining spring from brake caliper housing and remove. 1RWH 7LOW UHWDLQLQJ VSULQJ RXW RI D KROH LQ WKH KRXVLQJ E\ SUHVVLQJ LQ GLUHFWLRQ RI DUURZ DUURZ LV PDUNHG RQ UHWDLQLQJ VSULQJ DQG UHPRYH

- Disconnect harness connector -1- for brake pad wear indicator. - Lift securing strap slightly at bottom of connector -2- and then rotate 90 . - Remove bottom of connector from bracket and unclip wire from protective cap -3- for vent valve.
- Remove both guide pins from brake caliper. - Remove brake caliper housing and set aside so that the weight of the brake caliper does not burden or damage the brake hose. - Remove brake pads from brake caliper housing or from brake carrier.

,QVWDOOLQJ 1RWH 3UHVV SLVWRQ EDFN LQWR FDOLSHU KRXVLQJ XVLQJ UHVHWWLQJ WRRO EHIRUH LQVHUWLQJ QHZ EUDNH SDGV %HIRUH SXVKLQJ EDFN WKH SLVWRQ VLSKRQ VRPH RI WKH EUDNH IOXLG RXW RI WKH EUDNH IOXLG UHVHUYRLU 2WKHUZLVH HVSHFLDOO\ LI UHVHUYRLU KDV EHHQ WRSSHG RII IOXLG ZLOO RYHUIORZ DQG FDXVH GDPDJH - Press piston back. - Insert brake pad with retaining spring in brake caliper housing. - Place outer brake pad with wear indicator on brake carrier. - Tighten brake caliper housing to brake carrier using both guide pins (25 Nm). - Insert lower part of connector for brake pad wear indicator into bracket at brake caliper. - Install both protective caps.

- Place one bow of the retaining spring under the brake carrier and insert a tab into hole in housing (arrow A).Tension second bow under the brake carrier and engage second tab in hole (arrow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


1RWHV $IWHU UHSODFLQJ EUDNH SDGV DQG EHIRUH PRYLQJ YHKLFOH GHSUHVV EUDNH SHGDO VHYHUDO WLPHV ILUPO\ WR SURSHUO\ VHDW EUDNH SDGV LQ WKHLU QRUPDO RSHUDWLQJ SRVLWLRQ :KHQ VLSKRQLQJ EUDNH IOXLG DOZD\V XVH D EOHHGHU ERWWOH WKDW LV XVHG H[FOXVLYHO\ IRU EUDNH IOXLG %UDNH IOXLG LV SRLVRQRXV 1(9(5 VLSKRQ EUDNH IOXLG ZLWK \RXU PRXWK :KHHO EROW WLJKWHQLQJ WRUTXH 5HSDLU 0DQXDO 6XVSHQVLRQ :KHHOV 6WHHULQJ IURP P\ 5HSDLU *URXS 7LJKWHQLQJ WRUTXHV IRU ZKHHO EROWV +H[ EROW 1P

'ULYH D[OH With rotor for speed sensor :KHHO EHDULQJ KRXVLQJ $%6 ZKHHO VSHHG VHQVRU Before inserting sensor, clean inner surface of bore hole and coat with securing grease G 000 650 %UDFNHW 6RFNHWKHDG EROW 1P %DFNLQJ SODWH +H[ EROW 1P

%UDNH GLVF Brake disc thickness: 26 mm Wear limit: 22 mm Internally ventilated brake disc: 313 mm Always replace pads on both sides of axle if worn. Do not separate brake discs from wheel hub with force or rust solvent, otherwise brake discs will be damaged. +H[ EROW 5HSDLU 0DQXDO 6XVSHQVLRQ :KHHOV 6WHHULQJ IURP P\ 5HSDLU *URXS 'ULYH D[OHV VHUYLFLQJ 6RFNHW KHDG VFUHZ 1P

+DUQHVV FRQQHFWRU For pad replacement, remove from bracket, -item no. 22 %UDNH SDGV Thickness 14 mm Brake pad with retaining spring sits at piston - When the appropriate wear limit has been reached (limit: 2 to 3 mm), the warning lamp lights up Brake pad with adhesive foil on backing plate sits on outside Wear limit: 7 mm including backing plate Checking thickness 5HSDLU 0DQXDO 0DLQWHQDQFH :RUN SURFHGXUH GHVFULSWLRQ )URQW DQG UHDU EUDNH SDGV &KHFNLQJ WKLFNQHVV
Pads on both sides of axle must always be replaced together. Removing and installing Page
46-41

5HWDLQLQJ VSULQJ %UDNH FDUULHU Supplied as preassembled replacement part with sufficient grease on guide pins Use repair kit when protective caps are damaged. Use grease packet supplied to lubricate guide pins

%UDNH FDOLSHU Do not unscrew brake hose when replacing brake pad Removing: - Remove brake pads -item no. 13 - Page 46-41 - Insert VAG1869/2 brake pedal depressor - Unscrew brake hose -item no. 23 - from brake caliper Installing: - Install brake pads -item no. 13 - Page 46-42 - Attach brake hose -item no. 23 - at brake caliper - Remove VAG1869/2 brake pedal depressor - Bleed brake system Page 47-33 Servicing 47-19 Page
*XLGH SLQV 1P IW OE Removing and installing Page 46-41

&RQFHDOPHQW FDS %UDFNHW +H[ EROW 1P %UDNH OLQH ZLWK FRQQHFWLRQ QLSSOH %UDFNHW %UDNH KRVH +H[ EROW 1P


5HPRYLQJ 1RWH :KHQ UHPRYLQJ PDUN EUDNH SDGV WKDW ZLOO EH XVHG DJDLQ ,QVWDOO LQ WKH VDPH SRVLWLRQ RWKHUZLVH EUDNLQJ HIIHFW ZLOO EH XQHYHQ - Remove protective caps.
- Using screwdriver, pry off brake pad retaining spring from brake caliper housing (arrow) and remove. - Disconnect harness connector of brake pad wear indicator.
- Lift securing strap slightly at bottom of connector -1- and then rotate 90 . - Remove bottom of connector from bracket in direction of arrow.

- Remove both guide pins (arrows) from brake caliper. - Remove brake caliper housing and set aside so that the weight of the brake caliper does not burden or damage the brake hose. - Remove brake pads from brake caliper housing or from brake carrier. 8VH RQO\ DSSURSULDWH VROYHQWV IRU FOHDQLQJ EUDNH FDOLSHU KRXVLQJ ,QVWDOOLQJ 1RWH 3UHVV SLVWRQ EDFN LQWR FDOLSHU KRXVLQJ XVLQJ UHVHWWLQJ WRRO EHIRUH LQVHUWLQJ QHZ EUDNH SDGV %HIRUH SXVKLQJ EDFN WKH SLVWRQ VLSKRQ VRPH RI WKH EUDNH IOXLG RXW RI WKH EUDNH IOXLG UHVHUYRLU 2WKHUZLVH HVSHFLDOO\ LI UHVHUYRLU KDV EHHQ
WRSSHG RII IOXLG ZLOO RYHUIORZ DQG FDXVH GDPDJH - Press piston back. - Insert brake pad with retaining spring in brake caliper housing. - Install outer brake pad on brake carrier.

- Tighten brake caliper housing to brake carrier using both guide pins Page 46-34 . - Install both protective caps. - Install retaining spring in brake caliper housing. 1RWH $IWHU UHSODFLQJ EUDNH SDGV DQG EHIRUH PRYLQJ YHKLFOH DOZD\V GHSUHVV EUDNH SHGDO VHYHUDO WLPHV ILUPO\ WR SURSHUO\ VHDW EUDNH SDGV LQ WKHLU QRUPDO RSHUDWLQJ SRVLWLRQ &KHFN EUDNH IOXLG OHYHO DIWHU UHSODFLQJ EUDNH SDG

5HDU EUDNHV VHUYLFLQJ ZKHHOV

+H[ EROW Always replace after disassembly 5HSDLU 0DQXDO 6XVSHQVLRQ :KHHOV 6WHHULQJ IURP P\ 5HSDLU *URXS ZKHHO EHDULQJ VHUYLFLQJ )URQW DQG $OO :KHHO 'ULYH :DVKHU 6RFNHW KHDG EROW 1P %UDNH GLVF Thickness 12 mm Wear limit: 10 mm Always replace pads on both sides of axle if worn. +H[ EROW 1P

%DFNLQJ SODWH +H[ EROW 6SULQJ IRU EUDNH SUHVVXUH UHJXODWRU Adjusting brake pressure regulator Page 47-41 Not installed in vehicles with All Wheel Drive (AWD), ABS Bosch 5.3 and closed construction (box-type van, combi, caravelle, multivan) +H[QXW WLJKWHQ WR 1P 5HWDLQLQJ SODWH Mark installation position before removing %UDFNHW &RQWURO DUP Removing and installing 5HSDLU 0DQXDO 6XVSHQVLRQ :KHHOV 6WHHULQJ IURP P\ 5HSDLU *URXS 5HDU VXVSHQVLRQ VHUYLFLQJ

6HOIORFNLQJ KH[ QXW Always replace Only for Front Wheel Drive (FWD) vehicles 5HSDLU 0DQXDO 6XVSHQVLRQ :KHHOV 6WHHULQJ IURP P\ 5HSDLU *URXS ZKHHO EHDULQJ VHUYLFLQJ )URQW DQG $OO :KHHO 'ULYH 7HQVLRQ GLVF With rotor for speed sensor $%6 ZKHHO VSHHG VHQVRU 6RFNHW KHDG VFUHZ 1P +H[ EROW 1P :KHHO EHDULQJ 6QDS ULQJ Check for proper fitting :KHHO KXE

%UDNH FDUULHU ZLWK JXLGH SLQV DQG SURWHFWLYH FDS Vehicles up to VIN no. 70ZWH130 482 or 70ZWX121 939 without brake pad retention plates Supplied as preassembled replacement part with sufficient grease on guide pins If protective caps or guide pins are damaged, install repair kit. Use grease packet supplied to lubricate guide pins %UDNH SDGV Thickness: 11.5 without mounting plate Checking thickness: 5HSDLU 0DQXDO 0DLQWHQDQFH Wear limit: 2 mm without brake pad mounting plate (remaining pad thickness) Pads on both sides of axle must always be replaced together. Removing and installing Page
46-50

+H[ EROW VHOI ORFNLQJ 1P Always replace When loosening and tightening, counter-hold on guide pin *XLGH SLQV 3URWHFWLYH FDS %UDNH FDOLSHU Modification: Adapted for vehicles from VIN no. 70ZWH130 483 and 70ZWX121 940 with implementation of the brake pad retention plate item no. 29 - and brake carrier item no. 30 -. Servicing 47-25 Page
3DUNLQJ EUDNH FDEOH Parking brake, adjusting Page 46-55 6SULQJ FODPS

%UDNH SDG UHWHQWLRQ SODWH Installed in vehicles from VIN no. 70ZWH130 483 and 70ZWX121 940 Only install with new brake carrier -item no. 30 Always replace when pads are replaced %UDNH FDUULHU ZLWK JXLGH SLQV DQG SURWHFWLYH FDS Installed in vehicles from VIN no. 70ZWH130 483 and 70ZWX121 940 with implementation of the brake pad retention plate item no. 29 -. Supplied as preassembled replacement part with sufficient grease on guide pins If protective caps or guide pins are damaged, install repair kit. Use grease packet supplied to lubricate guide pins


5HPRYLQJ 1RWH :KHQ UHPRYLQJ PDUN EUDNH SDGV WKDW ZLOO EH XVHG DJDLQ ,QVWDOO LQ WKH VDPH SRVLWLRQ RWKHUZLVH EUDNLQJ HIIHFW ZLOO EH XQHYHQ - Remove wheels. - Remove parking brake cable at brake caliper.
- Unscrew attachment bolts (arrows) from brake caliper housing. - Remove brake caliper housing and set aside so that the weight of the brake caliper does not burden or damage the brake hose.

- Remove brake pads. - If present, remove brake pad retention plates. ,QVWDOOLQJ 1RWH %HIRUH SXVKLQJ EDFN WKH SLVWRQ VLSKRQ VRPH RI WKH EUDNH IOXLG RXW RI WKH EUDNH IOXLG UHVHUYRLU :KHQ VLSKRQLQJ EUDNH IOXLG DOZD\V XVH D SODVWLF EOHHGHU ERWWOH WKDW LV XVHG H[FOXVLYHO\ IRU EUDNH IOXLG %UDNH IOXLG LV SRLVRQRXV 1(9(5 VLSKRQ EUDNH IOXLG ZLWK \RXU PRXWK - Brake caliper housing hangs on a hook (arrow B). - Install pistons at knurled wheel of special tool -3272- by turning toward right. Do not damage protective caps. 1RWHV ,QVHUW VSHFLDO WRRO VR WKDW WKH FROODU DUURZ RI WKH WRRO UHVWV DW EUDNH FDOLSHU )RU SLVWRQV WKDW DUH GLIILFXOW WR PRYH DQ RSHQHQG ZUHQFK VL]H PP FDQ EH DSSOLHG DW WKH DSSURSULDWH ZUHQFK VXUIDFH DUURZ $ :KHQ SLVWRQ LV PLVDGMXVWHG ZLWK D SLVWRQ UHVHWWLQJ WRRO RU LI IRRW EUDNH LV RSHUDWHG WKH DXWRPDWLF UHVHW IXQFWLRQ RI WKH EUDNH FDOLSHU LV FRPSURPLVHG

)RU YHKLFOHV XS WR 9,1 QR =:+ DQG =:; - Thoroughly clean contact surfaces for brake pads at brake carrier, remove corrosion. - Insert brake pads in brake carrier.
- Using a feeler gauge -A-, measure play between brake pads -1- and contact surfaces for brake pads -2- at brake carrier.
Play: At least 0.4 mm to ensure proper function of brake system. If play is less than 0.4 mm, clean contact surfaces for brake pads at brake carrier again.
- Remove brake pads. - Lightly grease contact surfaces for brake pads using solid lubricant G000 650. - Insert brake pads in brake carrier.

)RU YHKLFOHV IURP 9,1 QR =:+ DQG =:; - Thoroughly clean contact surfaces for brake pad retention plates at brake carrier, remove corrosion. - Insert brake pad retention plates and brake pads in brake carrier. - Using a feeler gauge -A-, measure play between brake pads -1- and brake pad retention plates 2- at brake carrier.
Play: At least 0.4 mm to ensure proper function of brake system. If play is less than 0.4 mm, clean contact surfaces for brake pad retention plates at brake carrier again.

&RQWLQXDWLRQ IRU DOO YHKLFOHV
- Secure brake caliper housing using new selflocking bolts. 5HSDLU NLW LQFOXGHV IRXU VHOIORFNLQJ KH[EROWV ZKLFK PXVW DOZD\V EH LQVWDOOHG - Secure parking brake cable (arrow) at brake caliper housing. - Adjusting parking brake Page 46-55 .
'R QRW RSHUDWH IRRW EUDNH XQWLO DIWHU SDUNLQJ EUDNH LV DGMXVWHG - Mount wheels. 1RWHV $IWHU UHSODFLQJ EUDNH SDGV DQG EHIRUH PRYLQJ YHKLFOH DOZD\V GHSUHVV EUDNH SHGDO VHYHUDO WLPHV ILUPO\ WR SURSHUO\ VHDW EUDNH SDGV LQ WKHLU QRUPDO RSHUDWLQJ SRVLWLRQ &KHFN EUDNH IOXLG OHYHO DIWHU UHSODFLQJ EUDNH SDG

3DUNLQJ EUDNH DGMXVWLQJ

1RWH 2QO\ UHDGMXVW DIWHU UHSODFLQJ SDUNLQJ EUDNH FDEOHV EUDNH FDOLSHUV DQG EUDNH GLVFV - Parking brake lever in released position. Tighten adjustment nut (arrow) in until...
- ... the levers (arrow) lift off stops at brake calipers. - Maximum permitted play is 1.0 mm to stop. - Tighten parking brake and then release again. 1RWH %HFDXVH WKH UHDU EUDNHV KDYH DQ DXWRPDWLF DGMXVWPHQW IXQFWLRQ UHDGMXVWLQJ WKH SDUNLQJ EUDNH LV XVXDOO\ QRW QHFHVVDU\ IROORZLQJ LQLWLDO DGMXVWPHQW - Check whether wheels turn freely.

5HDU EUDNHV VHUYLFLQJ ZKHHOV

6RFNHW KHDG VFUHZ 1P +H[ EROW 1P $%6 ZKHHO VSHHG VHQVRU Before inserting sensor, clean inner surface of bore hole and coat with securing grease G 000 650 +DUQHVV FRQQHFWRU For pad replacement, remove from bracket, -item no. 7 &RQWURO DUP
+H[ EROW VHOI ORFNLQJ 1P Always replace When loosening and tightening, counter-hold on guide pin

%UDFNHW *XLGH SLQV 3URWHFWLYH FDS %UDNH SDGV Pads on both sides of axle must always be replaced together. With wear indicator - Warning lamp lights up when relevant wear limit has been reached Thickness: 13.5 mm Wear limit: 8.5 mm including backing plate Checking thickness: 5HSDLU 0DQXDO 0DLQWHQDQFH :RUN SURFHGXUH GHVFULSWLRQ )URQW DQG UHDU EUDNH
Removing and installing Page 46-61

%UDNH SDG UHWHQWLRQ SODWH Always replace when pads are replaced 5HWDLQLQJ VSULQJ Clip into brake caliper Secures wire for brake pad wear indicator %UDNH FDOLSHU Do not unscrew brake hose when replacing brake pad Removing: - Remove brake pads -item no. 10 - Page 46-61 - Insert VAG1869/2 brake pedal depressor - Unscrew brake hose with brake caliper Installing: - Install brake pads -item no.
10 - Page 46-63
- Attach brake hose with brake caliper - Remove VAG1869/2 brake pedal depressor - Bleed brake system Page 47-33

After servicing or replacing, parking brake cable must be adjusted first. Parking brake, adjusting Page 4655 Servicing 25 Page 47-
6SULQJ FODPS 3DUNLQJ EUDNH FDEOH %UDNH FDUULHU ZLWK JXLGH SLQV DQG SURWHFWLYH FDS Supplied as preassembled replacement part with sufficient grease on guide pins If protective caps or guide pins are damaged, install repair kit. Use grease packet
supplied to lubricate guide pins 6RFNHWKHDG EROW 1P

%UDNH GLVF Thickness: 13.5 mm Wear limit: 11.5 mm Always replace pads on both sides of axle if worn. +H[ EROW 1P %DFNLQJ SODWH Allocation 3DUWV FDWDORJ %DFNLQJ SODWH To remove, drill out pop rivet item no. 22 Allocation 3DUWV FDWDORJ 3RS ULYHW 4x &RQQHFWLQJ EUDFH


6SHFLDO 7RROV DQG (TXLSPHQW 3272 reset tool
VAG1331 torque wrench

1RWH :KHQ UHPRYLQJ PDUN EUDNH SDGV WKDW ZLOO EH XVHG DJDLQ ,QVWDOO LQ WKH VDPH SRVLWLRQ RWKHUZLVH EUDNLQJ HIIHFW ZLOO EH XQHYHQ 5HPRYLQJ - Remove wheels. - Unclip spring clamp -1-.
- Remove parking brake cable -2- from brake caliper. - Rotate harness connector for brake pad wear indicator by 90 and remove from cable channel toward side. - Disconnect harness connector for brake pad wear indicator.
- Unclip retaining spring -A- for brake pad wear indicator wire from brake caliper. - Unscrew attachment bolts (arrows) from brake caliper housing. - Remove brake caliper housing and set aside so that the weight of the brake caliper does not burden or damage the brake hose.

- Remove brake pads and brake pad retention plates (arrows). ,QVWDOOLQJ 1RWH %HIRUH SXVKLQJ EDFN WKH SLVWRQ VLSKRQ VRPH RI WKH EUDNH IOXLG RXW RI WKH EUDNH IOXLG UHVHUYRLU :KHQ VLSKRQLQJ EUDNH IOXLG DOZD\V XVH D SODVWLF EOHHGHU ERWWOH WKDW LV XVHG H[FOXVLYHO\ IRU EUDNH IOXLG %UDNH IOXLG LV SRLVRQRXV 1(9(5 VLSKRQ EUDNH IOXLG ZLWK \RXU PRXWK - Brake caliper housing hangs on a hook (arrow B).
- Install pistons at knurled wheel of special tool -3272- by turning toward right. Do not damage protective caps. ,QVHUW VSHFLDO WRRO VR WKDW WKH FROODU DUURZ RI WKH WRRO UHVWV DW EUDNH FDOLSHU )RU SLVWRQV WKDW DUH GLIILFXOW WR PRYH DQ RSHQHQG ZUHQFK VL]H PP FDQ EH DSSOLHG DW WKH DSSURSULDWH ZUHQFK VXUIDFH DUURZ $ :KHQ SLVWRQ LV PLVDGMXVWHG ZLWK D SLVWRQ UHVHWWLQJ WRRO RU LI IRRW EUDNH LV RSHUDWHG WKH DXWRPDWLF UHVHW IXQFWLRQ RI WKH EUDNH FDOLSHU LV FRPSURPLVHG

- Thoroughly clean contact surfaces for brake pad retention plates at brake carrier, remove corrosion. - Insert brake pad retention plates and brake pads in brake carrier. - Using a feeler gauge -A-, measure play between brake pads -1- and brake pad retention plates 2- at brake carrier.
Play: At least 0.4 mm to ensure proper function of brake system. If play is less than 0.4 mm, clean contact surfaces for brake pad retention plates at brake carrier again.
- Insert pad retaining springs (arrows) and brake pads, inner brake pad with wire for brake pad wear indicator, in the brake carrier. - Secure brake caliper housing using new selflocking bolts. 1RWH 5HSDLU NLW LQFOXGHV IRXU VHOIORFNLQJ KH[EROWV ZKLFK PXVW DOZD\V EH LQVWDOOHG

- Press brake lever -3- in direction of arrow and engage parking brake cable -2-. - Install spring clamp -1-. - Connect connection -5- for brake pad wear indicator and press it into the cable channel 4-. - Rotate harness connector in cable channel by 90 . - Adjusting parking brake Page 46-55 .
'R QRW RSHUDWH IRRW EUDNH XQWLO DIWHU SDUNLQJ EUDNH LV DGMXVWHG - Mount wheels. 1RWHV $IWHU UHSODFLQJ EUDNH SDGV DQG EHIRUH PRYLQJ YHKLFOH DOZD\V GHSUHVV EUDNH SHGDO VHYHUDO WLPHV ILUPO\ WR SURSHUO\ VHDW EUDNH SDGV LQ WKHLU QRUPDO RSHUDWLQJ SRVLWLRQ &KHFN EUDNH IOXLG OHYHO DIWHU UHSODFLQJ EUDNH SDG

3DUNLQJ EUDNH FDEOH UHPRYLQJ DQG LQVWDOOLQJ

)URQW SDUNLQJ EUDNH FDEOH UHPRYLQJ DQG LQVWDOOLQJ
5HPRYLQJ - Release parking brake. - Raise vehicle. - Remove nut (arrow) from front parking brake cable. - Pry both brackets out from underbody. - Remove trim from parking brake lever. - Place brake lever in upper end position. - Remove cable tie from locking latch.
- Disengage front parking brake lever from locking latch -1- (arrow).

,QVWDOOLQJ
- Guide front parking brake cable through underbody into interior. - Place brake lever in upper end position. - Engage front parking brake cable in locking latch -1- (arrow). - Attach new cable ties at locking latch in front of front parking brake. - Attach trim at parking brake lever. - Raise vehicle. - Clip brackets into underbody.
- Install nut (arrow) at front parking brake cable. - Adjusting parking brake Page 46-55 .

3XOOOHYHU UHPRYLQJ DQG LQVWDOOLQJ

5HPRYLQJ - Release parking brake. - Raise vehicle.
- Remove nut (arrow) from front parking brake cable. - Disengage pull-lever from compensator bracket.
- Remove pull-lever -1- from rear parking brake cable.

,QVWDOOLQJ - Engage pull-lever -1- in rear parking brake cable -2-. - Engage pull-lever in compensator bracket.
- Install nut (arrow) at front parking brake cable. - Adjusting parking brake Page 46-55 .

5HDU SDUNLQJ EUDNH FDEOH UHPRYLQJ DQG LQVWDOOLQJ

5HPRYLQJ - Unclip spring clamp -1-. - Remove parking brake cable -2- from brake caliper.
- Disengage parking brake cable from bracket at control arm (arrow A).

- Unclip parking brake cable from bracket at underbody (arrow). - Disengage parking brake cable -1- from pulllever -2-. ,QVWDOOLQJ
- Engage parking brake cable -1- in pull-lever 2-. - Clip parking brake cable into bracket at underbody.

- Engage parking brake cable in bracket at control arm (arrow A).
- Attach parking brake cable -2- at brake caliper. - Clip in spring clamp -1-. - Adjusting parking brake Page 46-55 .

3DUNLQJ EUDNH OHYHU UHPRYLQJ DQG LQVWDOOLQJ

+DQGOH Remove forward, first press retaining tabs under handle downward 7ULP IRU SDUNLQJ EUDNH OHYHU 7ULP %XWWRQ &RPSUHVVLRQ VSULQJ Installation position Fig. 1 6SULQJ VOHHYH Installation position Fig. 1 /DWFK URG /RFNLQJ ODWFK

/RFNLQJ ZDVKHU 3DUNLQJ EUDNH OHYHU 3LQ 6HOIORFNLQJ QXW 1P Not installed on Right Hand Drive (RHD) vehicles Always replace 3DUNLQJ EUDNH FDUULHU Welded to structure on Right Hand Drive (RHD) vehicles &RQWDFW VZLWFK ([SDQGLQJ ULYHW 6HOIORFNLQJ QXW 1P Always replace 7RRWKHG VHJPHQW Only for Right Hand Drive (RHD) vehicles 3XOOOHYHU

%UDFNHW 5HWXUQ VSULQJ 6SULQJ EUDFNHW $GMXVWPHQW QXW Parking brake, adjusting Page 46-55 3XOOFDEOH Only installed in platform trucks 3DUNLQJ EUDNH FDEOH

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,QVWDOODWLRQ SRVLWLRQ RI VSULQJ VOHHYH
1 - Locking latch 2 - Spring sleeve 3 - Compression spring Dimension -a- approx. 126 mm Slide spring sleeve -2- onto coil spring -3when installing. 4 - Button Screw in until stop.
5 - Latch rod 6 - Parking brake lever

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:$51,1* 7KH SDWK RI WKH EUDNH SHGDO PXVW QRW EH VKRUWHQHG YLD H[WUD IORRU PDWV 1RWH /XEULFDWH DOO EHDULQJ ORFDWLRQV ZLWK * OXEULFDQW EHIRUH LQVWDOOLQJ &DS %UDNH IOXLG UHVHUYRLU With sieve Switch for brake fluid level indicator integrated in reservoir 6HDOLQJ SOXJV Coat with brake fluid and press into expansion tank

+H[QXW WLJKWHQ WR 1P 7DQGHP PDVWHU EUDNH F\OLQGHU Cannot be serviced. Replace as complete unit if malfunctioning. Bleeding 47-35 6HDO Always replace /RFNLQJ ZDVKHU Check for secure fitting 3LQ Lubricate with G 000 602 6HOIORFNLQJ QXW 1P Always replace 3UHVVXUH URG ZLWK IRUNKHDGHG EUDNH ERRVWHU

Page
7DQGHP EUDNH ERRVWHU On gasoline engines vacuum is supplied from intake manifold. On diesel engines, a vacuum pump is installed for vacuum creation. Function test - With engine switched off, depress brake pedal firmly several times (to deplete vacuum in tool). - Depress and hold brake pedal with average foot pressure and start engine. If brake booster is working properly, pedal will be felt to give noticeably under foot (booster assistance becomes effective). If malfunctioning: replace as complete unit only. Check-valve (in vacuum hose) Page 47-55 Function test Page 47-55 Removing and
installing 47-59
Page

*DVNHW For tandem brake booster /RFNLQJ ZDVKHU 5HWXUQ VSULQJ IRU EUDNH SHGDO %XVKLQJ IRU EUDNH SHGDO %UDNH SHGDO 3LYRW SLQ IRU EUDNH SHGDO %UDNH OLJKW VZLWFK Secure brake pedal at pressure rod of brake booster before installing brake light switch Before installing, remove plunger completely Guide switch through assembly hole and install by rotating 90 toward right.

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1RWHV /XEULFDWH DOO EHDULQJ DQG FRQWDFW VXUIDFHV ZLWK 0R6 OXEULFDQW 5HPRYH RQO\ WKH IRUNKHDG FRQQHFWLRQ WR EUDNH SHGDO ZKHQ UHPRYLQJ WKH EUDNH ERRVWHU 5HPRYLQJ - Remove covers before removing brake pedal.
- Remove brake light switch. - Remove securing disc at pins for fork-head connection to brake pedal. - Remove pins. - Remove securing disc of pivot pins for clutch and brake pedal. - Remove clutch pedal.
5HSDLU 0DQXDO 0DQXDO 7UDQVPLVVLRQ 5HSDLU *URXS &OXWFK PHFKDQLVP VHUYLFLQJ 5HPRYLQJ DQG LQVWDOOLQJ FOXWFK SHGDO - Remove pivot pins. - Remove brake pedal.

,QVWDOOLQJ - Installation is the reverse of removal. - Adjust brake light switch no. 18 . Page 46-80 , item

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- Force piston from brake caliper housing using compressed air. 1RWH 3ODFH D ZRRGHQ ERDUG LQWR WKH UHFHVV RI WKH FDOLSHU KRXVLQJ WR FDWFK WKH SLVWRQ VR LW LV QRW GDPDJHG

- Removing seal using 3409 assembly wedge. 1RWH :KHQ UHPRYLQJ PDNH VXUH WKDW VXUIDFH RI F\OLQGHU LV QRW GDPDJHG ,QVWDOOLQJ - Use only appropriate solvent to clean surfaces of piston and protective seal, then dry. - Apply thin coat of brake cylinder paste G 052 150 A2 to piston and protective seal before installing. - Install sealing ring in brake caliper housing.
- Place protective cap with outer sealing lip on piston.

- Using 3409 assembly wedge, insert inner sealing lip into cylinder groove. 1RWH +ROG SLVWRQ LQ IURQW RI FDOLSHU KRXVLQJ IRU WKLV SURFHGXUH
- Press piston into brake caliper housing using piston resetting tool. 1RWH 2XWHU VHDOLQJ OLS RI SURWHFWLYH FDS ZLOO WKHQ HQJDJH LQ SLVWRQ JURRYH

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- Insert inner sealing lip into cylinder groove. 1RWH +ROG SLVWRQ LQ IURQW RI FDOLSHU KRXVLQJ IRU WKLV SURFHGXUH

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1RWHV ,QVWDOO FRPSOHWH UHSDLU NLW ZKHQ VHUYLFLQJ $SSO\ D WKLQ FRDW RI EUDNH F\OLQGHU SDVWH * $ WR EUDNH F\OLQGHUV SLVWRQV DQG VHDOV 'XVW FDS Push onto bleeder valve %OHHGHU YDOYH Apply thin coat of brake cylinder paste G 052 150 A2 to threads before screwing in &DSV Insert in mounting bushing *XLGH SLQV 1P IW OE %HDULQJ EXVKLQJ Insert in brake caliper housing

%UDNH FDOLSHU KRXVLQJ %UDNH FDUULHU Bolt to brake caliper housing 5HWDLQLQJ VSULQJ Insert with both ends in holes of brake caliper housing 6HDO Removing and installing Page 47-11 3LVWRQV Removing and installing Page 47-11 3URWHFWLYH FDS Do not damage when installing piston

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1RWHV ,QVWDOO FRPSOHWH UHSDLU NLW ZKHQ VHUYLFLQJ $SSO\ D WKLQ FRDW RI EUDNH F\OLQGHU SDVWH * $ WR EUDNH F\OLQGHUV SLVWRQV DQG VHDOV 'XVW FDS Push onto bleeder valve Secures wire for brake pad wear indicator %OHHGHU YDOYH Apply thin coat of brake cylinder paste G 052 150 A2 to threads before screwing in &DSV Insert in mounting bushing *XLGH SLQV 1P IW OE

%HDULQJ EXVKLQJ Insert in brake caliper housing %UDNH FDOLSHU KRXVLQJ %UDNH FDUULHU Bolt to brake caliper housing 5HWDLQLQJ VSULQJ Insert with both ends in holes of brake caliper housing 6HDO Removing and installing Page 47-16 3LVWRQV Removing and installing Page 47-16 3URWHFWLYH FDS Do not damage when installing piston





1RWHV ,QVWDOO FRPSOHWH UHSDLU NLW ZKHQ VHUYLFLQJ 1HZ EUDNH FDOLSHUV DUH ILOOHG ZLWK EUDNH IOXLG DQG DUH SUHEOHG $SSO\ D WKLQ FRDW RI EUDNH F\OLQGHU SDVWH * $ WR EUDNH F\OLQGHUV SLVWRQV DQG VHDOV 'XVW FDS Push onto bleeder valve Secures wire for brake pad wear indicator %OHHGHU YDOYH Apply thin coat of brake cylinder paste G 052 150 A2 to threads before screwing in &DSV Insert in mounting bushing

*XLGH SLQV 1P IW OE %HDULQJ EXVKLQJ Insert in brake caliper housing 2x %UDNH FDOLSHU KRXVLQJ %UDNH FDUULHU Bolt to brake caliper housing 5HWDLQLQJ VSULQJ Insert both ends between exterior of brake caliper housing and inner part of brake caliper housing Insert center in strap at brake pad 6HDO Removing and installing Page 47-22

3LVWRQV Removing and installing Page 47-22 Apply thin coat of brake cylinder paste G 052 150 A2 before installing Piston diameter: 57 mm 3URWHFWLYH FDS Do not damage when installing piston

6SHFLDO 7RROV DQG (TXLSPHQW 3409 wedge Brake piston resetting tool 5HPRYLQJ

- Removing seal using 3409 assembly wedge. 1RWH :KHQ UHPRYLQJ PDNH VXUH WKDW VXUIDFH RI F\OLQGHU LV QRW GDPDJHG ,QVWDOOLQJ - Use only appropriate solvent to clean surfaces of piston and protective seal, then dry. - Apply thin coat of brake cylinder paste G 052 150 A2 to piston and protective seal before installing. - Install sealing ring in brake caliper housing. - Place protective cap with outer sealing lip on piston.


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1RWHV ,QVWDOO FRPSOHWH UHSDLU NLW ZKHQ VHUYLFLQJ 1HZ EUDNH FDOLSHUV DUH ILOOHG ZLWK EUDNH IOXLG DQG DUH SUHEOHG $SSO\ D WKLQ FRDW RI EUDNH F\OLQGHU SDVWH * $ WR EUDNH F\OLQGHUV SLVWRQV DQG VHDOV ,Q FDVH RI UHSDLU EUDNH FDOLSHUV PXVW DOZD\V EH SUHEOHG EHIRUH EHLQJ LQVWDOOHG LQWR YHKLFOH ZLWKRXW EUDNH SDGV 3DJH +H[ EROW VHOI ORFNLQJ 1P Always replace When loosening and tightening, counter-hold on guide pin

6HDO Removing and installing Page 47-28 3LVWRQ ZLWK DXWRPDWLF DGMXVWPHQW Removing and installing Page 47-28 3URWHFWLYH FDS Pull onto piston with outer sealing lip 'XVW FDS %OHHGHU YDOYH %UDNH FDOLSHU KRXVLQJ ZLWK SDUNLQJ EUDNH FDEOH OHYHU Replace if leaking at parking brake cable lever Pre-bleed caliper housing after repairing Page 47-31

*XLGH SLQV Grease before pulling on protective cap 3URWHFWLYH FDS Pull onto brake carrier and guide pin %UDNH FDUULHU ZLWK JXLGH SLQV DQG SURWHFWLYH FDS Supplied as preassembled replacement part with sufficient grease on guide pins If protective caps or guide pins are damaged, install repair kit. Use grease packet supplied to lubricate guide pins.

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3409 wedge Bleeder bottle

5HPRYLQJ - Remove piston from brake caliper housing by turning knurled wheel toward left. Do not damage protective cap. 1RWHV ,QVHUW VSHFLDO WRRO VR WKDW WKH FROODU DUURZ RI WKH WRRO UHVWV LQ IURQW RI SLVWRQ )RU SLVWRQV WKDW DUH GLIILFXOW WR PRYH DQ RSHQ HQG ZUHQFK VL]H PP FDQ EH DSSOLHG DW WKH DSSURSULDWH ZUHQFK VXUIDFH DUURZ $ - Removing seal using 3409 assembly wedge.

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- Use only appropriate solvent to clean surfaces of piston and protective seal, then dry. - Apply thin coat of brake cylinder paste G 052 150 A2 to piston and protective seal before installing. - Install sealing ring in brake caliper housing. - Place protective cap with outer sealing lip on piston.

- Install pistons at knurled wheel by turning toward right. Do not damage protective caps. 1RWHV ,QVHUW VSHFLDO WRRO VR WKDW WKH FROODU DUURZ RI WKH WRRO UHVWV DW EUDNH FDOLSHU )RU SLVWRQV WKDW DUH GLIILFXOW WR PRYH DQ RSHQHQG ZUHQFK VL]H PP FDQ EH
DSSOLHG DW WKH DSSURSULDWH ZUHQFK VXUIDFH DUURZ $ :KHQ SLVWRQ LV PLVDGMXVWHG ZLWK D SLVWRQ UHVHWWLQJ WRRO RU LI IRRW EUDNH LV RSHUDWHG WKH DXWRPDWLF UHVHW IXQFWLRQ RI WKH EUDNH FDOLSHU LV FRPSURPLVHG - Insert brake pads. 3UHEOHHGLQJ EUDNH FDOLSHU - Open bleeder valve (arrow -A-) and fill with brake fluid using standard bleeder bottle until brake fluid flows out of threaded hole (end of brake hose, arrow -B-) without bubbles. Close bleeder screw. 1RWH 3RVLWLRQ EUDNH FDOLSHU DV VKRZQ GXULQJ SUHEOHHG SURFHGXUH

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6SHFLDO 7RROV DQG (TXLSPHQW VAG1310A brake pressure gauge 0-250 bar 7HVW UHTXLUHPHQW Function and proper seal of brake system (hydraulic unit, brake hoses, brake lines and brake calipers) OK. - Remove bleeder screw at one front brake caliper. Connect pressure gauge from VAG1310A and bleed. - Apply pressure to brake pedal until gauge indicates positive pressure of 50 bar (725 psi). Pressure must not drop by more than 4 bar (58 psi) during test period of 45 seconds. If drop in pressure exceeds specification: replace main brake cylinder.

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'HVFULSWLRQ FRYHUV EOHHGLQJ RI EUDNH V\VWHP XVLQJ WKH 86 EUDNH EOHHGHU WRRO 6SHFLILFDOO\ IRU YHKLFOHV ZLWK $%6('6 If one chamber of the brake fluid reservoir has run completely empty (e.g. leak in the brake system), the hydraulic unit must be bled using the "basic setting" function and the VAG1551 Scan Tool (ST). :$51,1* )RU YHKLFOHV ZLWK $%6('6 :KHQ DGGLQJ EUDNH IOXLG XVLQJ WKH 86 EUDNH EOHHGHU WRRO EH VXUH QRW WR H[FHHG D ILOOLQJ SUHVVXUH RI EDU Brake fluid pressure must therefore be regulated down to 1 bar at the US1116 brake bleeder tool. operating instructions for US1116 Hydraulic unit may not be bled properly if a filler pressure of 1 bar is exceeded.

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6SHFLDO 7RROV DQG (TXLSPHQW US1116 brake bleeder tool

1RWHV 9HQWLQJ WKH EUDNH V\VWHP RQ YHKLFOHV ZLWK $%6 LV GRQH WKH VDPH DV IRU YHKLFOHV ZLWK FRQYHQWLRQDO EUDNH V\VWHPV ,I WKH PDVWHU EUDNH F\OLQGHU ZDV UHPRYHG RU UHSODFHG EOHHG EUDNH V\VWHP ILUVW 3URFHHG DV GHVFULEHG LQ ZRUN SURFHGXUH 9HQWLQJ EUDNH V\VWHP ZLWKRXW WKH EUDNH ILOOHU DQG EOHHGHU WRRO 3DJH - Connect US1116 brake bleeder tool. - Insert VAG1869/2 brake pedal depressor. - Open bleeder screws in the prescribed sequence and bleed brake caliper. 8VH DSSURSULDWH EOHHGHU KRVH ,W PXVW ILW WLJKWO\ RQ WKH YHQW VFUHZ VR WKDW QR DLU JHWV LQWR WKH EUDNH V\VWHP - With bleeder bottle hose attached, leave vent screws on one brake caliper open long enough that brake fluid exits without bubbles.

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1 - rear right brake caliper 2 - rear left brake caliper 3 - Front right brake caliper 4- Front left brake caliper 9HKLFOHV ZLWK $%6 RU $%6('/ 7KHVH YHKLFOHV PXVW EH URDG WHVWHG IROORZLQJ EOHHGLQJ SURFHGXUH $W OHDVW RQH $%6 FRQWUROOHG EUDNLQJ PXVW EH SHUIRUPHG 1RWH )RU YHKLFOHV ZLWK EUDNH ERRVWHU PRYH ERRVWHU OHYHU ZKHQ EOHHGLQJ UHDU EUDNHV

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- Build pressure in brake system by operating (pumping) brake pedal. - Open bleeder screw with bleeder bottle hose attached and pedal depressed. - Run brake fluid through by pumping pedal. Be sure there is sufficient supply in the brake fluid reservoir. - Close bleeder screw with pedal depressed. - Repeat procedure until no more air exits, but at least 3x per brake caliper. Bleeding sequence Page 47-37
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Page
3XOOVSULQJ Note installed position Note allocation 5HSDLU 0DQXDO 6XVSHQVLRQ :KHHOV 6WHHULQJ IURP P\ 5HSDLU *URXS $OORFDWLRQ RI FRLO VSULQJV DQG SXOOVSULQJ RI EUDNH ERRVWHU &OLS %DODQFH DUP Slight crookedness is permitted Page 47-47 6WRS EXIIHU Adjusting 47-48 &RQWURO DUP

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6SHFLDO 7RROV DQG (TXLSPHQW 3255 adjusting fixture 3257 plug insert (27mm) VAG1310A brake pressure gauge 0250 bar

%UDNH SUHVVXUH UHJXODWRU EDVLF VHWWLQJ 1RWHV ,I IRU H[DPSOH RQH RU ERWK FRQWURO DUPV LV EHLQJ UHSODFHG DQG WKHUH DUH QR PDUNLQJV RQ WKH FRQWURO DUP IRU WKH LQVWDOODWLRQ SRVLWLRQ RI WKH VSULQJ PRXQW ZH UHFRPPHQG SURFHHGLQJ DV GHVFULEHG EHORZ ,I EDVLF VHWWLQJ LV QRW UHTXLUHG SHUIRUP ILQH DGMXVWPHQW RI EUDNH ERRVWHU 3DJH - Remove both shock absorbers.
5HSDLU 0DQXDO 6XVSHQVLRQ :KHHOV 6WHHULQJ IURP P\ 5HSDLU *URXS 5HDU VXVSHQVLRQ VHUYLFLQJ 5HPRYLQJ DQG LQVWDOOLQJ VKRFN DEVRUEHUV - Insert 3255 adjusting fixture and pretension control arm Page 47-44 . - Bring balance arm -4- into balance by eyesight. Then rotate both stop buffers -1- upward until impact at balance arm -4- (no pre-tension at stop buffers -1-).

- Move one of the spring mounts -2- far enough downward that a gap (arrow) of approx. 2 mm results on the opposite side between stop buffer -1- and balance arm -4-. - Move second spring mount -2- far enough downward that balance arm -4- is balanced again. - Rotate both stop buffers -1- completely, so that the largest possible gap results between balance arm -4- and stop buffers -1-. - Continue with fine adjustment of brake pressure regulator Page 47-43 . )LQH DGMXVWPHQW RI EUDNH SUHVVXUH UHJXODWRU - Remove both shock absorbers. 5HSDLU 0DQXDO 6XVSHQVLRQ :KHHOV 6WHHULQJ IURP P\ 5HSDLU *URXS 5HDU VXVSHQVLRQ VHUYLFLQJ 5HPRYLQJ DQG LQVWDOOLQJ VKRFN DEVRUEHUV
- Slide 3255/1 pipes onto adjustment fixture.

- Insert 3255 adjusting fixture with 3255/1 pipes as shown in illustration. 1RWHV /XEULFDWH VSLQGOH WKUHDGV IDFH RI QXW DQG VXUIDFH RI GLVF XVLQJ 0R6 ,QVHUW D UXEEHU EXVKLQJ IURP WKH LPSDFW DEVRUEHU EHWZHHQ WKH ZDVKHU DUURZ DQG WKH FRQWURO DUP WR WHQVLRQ WKH FRQWURO DUP 'R QRW XVH DQ LPSDFW ZUHQFK )RU PDOIXQFWLRQV UHDU D[OH EUDNHV WRR ZHDNO\ RU WRR VWURQJO\ FKHFN VWRS EXIIHU DGMXVWPHQW ILUVW 3DJH

- Pre-tension control arm to dimension -x- using 3255 adjusting fixture. 1 - Base plate 2 - Spring 3 - Control arm 1RWHV 0HDVXUHPHQW H[WHQGV IURP SODWH HGJH LQ VSULQJ PRXQW DUURZ D WR XSSHU HGJH RI DVVHPEO\ KROH LQ FRQWURO DUP DUURZ E $GMXVW GLPHQVLRQ [ DFFRUGLQJ WR WDEOH 3DJH &RLO VSULQJ PD\ EH UHPRYHG WR DGMXVW FRQWURO DUP WR GLPHQVLRQ [ - Continue checking brake pressure 46 . Page 47-

&KHFNLQJ EUDNH SUHVVXUH - Connect VAG1310A pressure gauge at brake caliper (front left wheel) and at brake caliper (rear left wheel). - Bleed both gauges (bleeding brake system Page 47-33 ). - Depress brake pedal and measure pressures.
Front axle: 50 bar positive pressure Rear axle: 20 2 bar positive pressure
- Adjust if necessary
Page 47-47 . Page 47-48
- Continue adjusting stop buffers
.

$GMXVWLQJ EUDNH SUHVVXUH - Rotate both stop buffers -1- back to stop (downward). - Mark position of spring mount -2- on control arm using felt pen or adhesive tape. - Loosen screw -3- and shift mount -2-.
Shift spring mount -2- downward - pressure increase. Shift spring mount -2- upward - pressure decrease.
,W LV RQO\ QHFHVVDU\ WR DGMXVW WKH VHFRQG VSULQJ PRXQW LI WKH EDODQFH DUP LV YHU\ FURRNHG PRUH WKDQ PP DUURZV PP DGMXVWPHQW WUDYHO RI VSULQJ PRXQW UHSUHVHQWV DSSUR[ EDU SUHVVXUH FKDQJH DW UHDU D[OH - Slight crookedness of balance arm -4- is permitted (max. 4 mm between left and right arrows). - Tighten bolt -3-, counterhold when tightening. - Correct brake pressure regulator adjustment at second spring mount -2- if necessary.

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Page 47-48 .
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- Check brake pressure (unless already completed) Page 47-46 . - If adjustment is OK, insert pedal supports. - Maintain brake pressure at front axle of at least 50 bar. - Rotate both stop buffers -1- upward (Fig. shows only one stop buffer) using socket head wrench (6 mm) until a gap of 0.5 mm is measured between stop buffer -1- and balance arm -4- on both sides simultaneously using feeler gauge -5-. - Remove VAG1310A and bleed brake system Page 47-33 . - Remove 3255 adjusting fixture. - Install shock absorbers. 5HSDLU 0DQXDO 6XVSHQVLRQ :KHHOV 6WHHULQJ IURP P\ 5HSDLU *URXS 5HDU VXVSHQVLRQ VHUYLFLQJ 5HPRYLQJ DQG LQVWDOOLQJ VKRFN DEVRUEHUV

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280 mm 281 mm 284 mm 292 mm

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*HQHUDO ,QIRUPDWLRQ A brake test on the dynamometer cannot equate 100% to real conditions during a braking procedure on the street. Due to the relatively high weight difference between front and rear axle, it is normal to obtain a high measured value at the front axle. Vehicles with low rear axle loads will achieve only low braking power at rear axle. In addition, driving-related braking influences like load shift, relative friction, road conditions etc. are not reproducible on a dynamometer. The following table shows the minimum braking power at rear axle, dependent on the actual axle load with vehicle stationary. The braking power indications in the following table represent standard braking thresholds. The table lists the lowest tolerance value that must be achieved. It is always obtained or exceeded for a properly functioning brake system.

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5HDU D[OH ORDG ZHLJKHG 0LQLPXP EUDNLQJ SRZHU DW UHDU D[OH (both rear wheels) smaller than 600 kg 700 kg 800 kg 900 kg 1000 kg 1100 kg 1200 kg 1300 kg 1400 kg 1500 kg 1800 kg 900 N 1200 N 1500 N 1800 N 2200 N 2500 N 2800 N 3100 N 3300 N 3700 N 4000 N

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1RWH &RPSOHWH PDVWHU F\OLQGHUV DQG EUDNH ERRVWHUV FDQ EH UHSODFHG LQGHSHQGHQWO\ 7DQGHP EUDNH ERRVWHU On gasoline engines vacuum is supplied from intake manifold. On diesel engines, a vacuum pump is installed for vacuum creation. Function test - With engine switched off, depress brake pedal firmly several times (to deplete vacuum in tool).

- Depress and hold brake pedal with average foot pressure and start engine. If brake booster is working properly, pedal will be felt to give noticeably under foot (booster assistance becomes effective). If malfunctioning: replace as complete unit only. Check-valve (in vacuum hose) Page 47-55 Function test Page 47-55 Removing and installing Page 47-59 6HDO Always replace %UDNH IOXLG UHVHUYRLU &DS 6HDOLQJ SOXJV Coat with brake fluid and press into expansion tank

5HWDLQLQJ SLQ Insert through master brake cylinder 7DQGHP PDVWHU EUDNH F\OLQGHU Cannot be serviced. Replace as complete unit if malfunctioning. 6HOIORFNLQJ QXW 1P %UDFNHW 6HOIORFNLQJ QXW 1P

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- Check check-valve -A-. Valve must allow air to flow in direction of arrow. Valve must remain closed for opposite direction. Observe correct installation position. Illustration shows vacuum line from 111 kW TDI engine. Vacuum line is different depending on engine version, allocate according to replacement parts catalog.

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6SHFLDO 7RROV DQG (TXLSPHQW 3094 hose clamp 5HPRYLQJ - For vehicles equipped with coded anti-theft radio, note radio code, obtain if necessary. - Disconnect battery. - Place sufficient lint-free cloths around engine and transmission. - Attach bleeder hose to left-front brake caliper bleeder screw and open bleeder screw. - By operating brake pedal, pump out enough brake fluid that the brake fluid level in the brake fluid reservoir sinks below the return hose. - Close front left bleeder screw. - Clamp supply hose of clutch master cylinder shut using special tool 3094.

- Disconnect supply hose for clutch master cylinder. - Disconnect harness connector for brake fluid level warning switch. - Disconnect brake lines on brake master cylinder and seal brake lines using plugs from repair kit, Part No. 1H0 698 311 A. - Unscrew nuts from master brake cylinder.
- Carefully remove master brake cylinder from brake booster. ,QVWDOOLQJ - Installation is the reverse of removal. Take special notice of the following points when installing: - When installing master brake cylinder onto brake booster, make sure push rod is correctly located in master brake cylinder. - Bleed brake system and clutch after installing Page 47-33 .
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7LJKWHQLQJ WRUTXH Master brake cylinder at brake booster 47-52 Page

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3094 hose clamp 5HPRYLQJ - For vehicles equipped with coded anti-theft radio, note radio code, obtain if necessary. - Disconnect battery. - Place sufficient lint-free cloths around engine and transmission. - Attach bleeder hose to left-front brake caliper bleeder screw and open bleeder screw. - By operating brake pedal, pump out enough brake fluid that the brake fluid level in the brake fluid reservoir sinks below the return hose. - Close front left bleeder screw. - Clamp supply hose of clutch master cylinder shut using special tool 3094.

- Disconnect supply hose for clutch master cylinder. - Disconnect harness connector for brake fluid level warning switch. - Disconnect brake lines on brake master cylinder and seal brake lines using plugs from repair kit, Part No. 1H0 698 311 A.
- Disconnect connections for brake lines (arrows). - Disengage wire -1- from bracket -2-. - Unbolt engine coolant expansion tank and lay aside. Do not open coolant system. - Disconnect vacuum hose from brake booster. - Remove driver-side cover.
- Remove securing disc -1- at pins for fork-head connection to brake pedal. - Remove pins. - Remove brake booster (arrows). - Thread brake booster out with master brake cylinder toward front and remove.

,QVWDOOLQJ Installation is the reverse of removal. - Bleed brake system and clutch after installing Page 47-33 .
5HSDLU 0DQXDO 0DQXDO 7UDQVPLVVLRQ 5HSDLU *URXS &OXWFK PHFKDQLVP VHUYLFLQJ EOHHGLQJ FOXWFK V\VWHP 7LJKWHQLQJ WRUTXH Brake booster at cross panel Page 47-52

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These definitions are relevant only to the structural unit: Brake systems. They are not intended to be generally applicable. $%6 Anti-lock Brake System (ABS). More information on this can be found in self-study programs no. 117 and no. 148. $%6('/ Anti-lock Brake System with Electronic Differential Lock. More information on this can be found in the appropriate self-study program, no. 148. $65 $QWL6OLS 5HJXODWLRQ More information on this can be found in selfstudy program no. 115. $%6 ZKHHO VSHHG VHQVRU The wheel speed sensors transmit the speed signals to the control module. 2Q %RDUG 'LDJQRVWLF 2%' SHUIRUPLQJ Connect Scan Tool (ST) to check DTC memory. More information on this can be found in selfstudy programs no. 180 and in the Scan Tool (ST) operating instructions.

(63 (OHFWURQLF 6WDELOLW\ 3URJUDP ESP recognizes critical driving conditions and stabilizes the vehicle via wheel-independent braking and intervening in engine control. This occurs independently of the driver operating the brake or accelerator pedal. A description of the construction and function of the ESP system is included in self study program no. 204. 6HQGHU IRU URWDWLRQ UDWH
The sensor for rotation rate calculates vehicle rotation behavior around the vertical axis relative to vehicle speed. At a rotation of more than 4 /s, ESP regulation intervenes. 6WHHULQJ DQJOH VHQVRU The steering angle sensor recognizes the steering angle, which represents the wheel deflection and thereby indicates the direction of travel desired by the driver.

/DWHUDO DFFHOHUDWLRQ VHQVRU Recognizes the curve speed and helps determine where braking should occur via ESP.

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Brake System from m.y. 1997 Brake System On Board Diagnostic (OBD) from m.y.

00 - General, Technical data

45 - Anti-lock brake system

46 - Brakes - Mechanical components

47 - Brakes - Hydraulic components

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- Bleed brake system

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