D4B80416632 Brake System

Service
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - General, Technical Data
45 - Antilock Brake System
46 - Mechanical Components
47 - Hydraulic Components
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Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2016 Volkswagen AG, Wolfsburg D4B80416632

Golf 2015 ➤ , Golf Variant 2015 ➤
Brake System - Edition 12.2015
Contents
00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety Precautions during Road Test with Testing Equipment . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Safety Precautions when Working on Vehicles with Start/Stop System . . . . . . . . . . . . . . 1
2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 PR Number Allocation - Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Brakes Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Brakes Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.2 Front Wheel Drive Vehicles, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
45 - Antilock Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.1 ABS Repair Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 Component Location Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.1 Component Location Overview - ABS/ESP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 Control Module and Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 Overview - Control Module and Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 ABS Control Module J104 / ABS Hydraulic Unit N55 , Removing and Installing . . . . . . . . 17
3.3 Control Module, Separating from Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.4 Control Module, Attaching to Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.5 Brake Lines, Attaching to Hydraulic Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.1 Overviewn -AGFront
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Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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4.2 Overview
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4.3ised b Right/Left Front ABS Wheel SpeedarSensor an G45 / G47 , Removing and Installing . . . . . . 37
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4.6 Steering Angle Sensor G85 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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4.7 ABS Sensor Ring, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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46 - Mechanical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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1 Front Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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1.1 Overview - Front Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

1.2 Brake Pads, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1.3 Brake Caliper, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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1.4 Brake Carrier, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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1.5 Brake Rotor, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

1.6 Brake Shield, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
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2 Rear Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.1 Overview - Rear Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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2.2 Brake Pads, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

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2.3 Brake Caliper, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

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2.4 Brake Carrier, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

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2.5 Brake Rotor, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

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2.6 Brake Shield, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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3 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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3.1 Overview - Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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3.2 Parking Brake, Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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Contents i
3.3 Rear Brake Cable, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

4 Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.1 Overview - Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.2 Brake Pedal, Removing from Brake Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.3 Brake Pedal, Attaching to Brake Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.4 Brake Pedal, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.5 Mounting Bracket, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
47 - Hydraulic Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1 Front Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.1 Overview - Front Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
1.2 Brake Caliper Piston, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2 Rear Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.1 Overview - Rear Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.2 Brake Caliper Piston, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3 Brake Booster/Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.1 Overview - Brake Booster/Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.2 Brake Lamp Switch, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.3 Brake Master Cylinder, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
3.4 Brake Booster, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.5 Brake Fluid Reservoir, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
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4.4 Vacuum System, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

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5 Brake Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

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5.1 Brake Lines, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

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6 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

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6.1 Brake Fluid General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

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6.2 Hydraulic System, Standard Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

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6.3 Hydraulic System, Post-Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

6.4 Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
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7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

8 Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
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ii Contents
00 – General, Technical Data

1 Safety Precautions
(Edition 12.2015)
⇒ “1.1 Safety Precautions during Road Test with Testing Equip‐
ment”, page 1
⇒ “1.2 Safety Precautions when Working on Vehicles with Start/
Stop System”, page 1
1.1 Safety Precautions during Road Test

with Testing Equipment
If the Use of Testing Equipment Is Required on Road Tests, Note
the Following:
WARNING
Distraction and unsecured testing equipment increase the risk

of an accident.
♦ Operating testing equipment while driving causes distrac‐
tions.
♦ Testing equipment that is not secure increases the risk of
injury.
♦ Always secure atesting
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♦ The deployment of the front passenger airbag during an

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1.2 Safety Precautions when Working on

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Vehicles with Start/Stop System

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Note the following When Working on Vehicles with a Start/Stop

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♦ Therefore, make sure that the Start/Stop System is deac‐

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1. Safety Precautions 1
2 Identification
⇒ “2.1 PR Number Allocation - Brakes”, page 2
2.1 PR Number Allocation - Brakes

⇒ “2.1.1 General Information”, page 2
⇒ “2.1.2 Front Brakes”, page 2
⇒ “2.1.3 Rear Brakes”, page 2
2.1.1 General Information

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In this example, the vehicle has “1KU” rear brakes.
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♦ For allocation. Refer to the Parts Catalog.
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♦ The following tables explain the PR numbers. These are im‐
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2.1.2 Front Brakes

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1ZE/1ZP PC57 (15”)

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2.1.3 Rear Brakes
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Rear Axle PR Number Rear Brakes

Torsion Beam Rear Suspension 1KD C 38
Torsion Beam Rear Suspension 1KD/1KQ CI 38 (15”)
Torsion Beam Rear Suspension 1KD/1KQ CI 38 HRA
Multi-Link Rear Axle 1KS/1KT PC 38 HRA
Multi-Link Rear Axle 1KS/1KT TRW
2 Rep. Gr.00 - General, Technical Data

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⇒ “3.1 Brakes Technical Data”, page au 3 ac
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⇒ “3.1.1 Brake Master Cylinder and Brake Booster”, page 3
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⇒ “3.1.2 Front Brakes”, page 3
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⇒ “3.1.3 Rear Brakes”, page 5
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3.1.1 Brake Master Cylinder and Brake Boos‐
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Brake master cylinder, Diameter in mm 23.81 or 25.4
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Brake booster, depend‐ Diameter in in‐ 10 or 11
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Front Brakes PC57 (15”)
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Item PR Number 1ZE/1ZP

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2 Brake pad, mm 14
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Brake pad, wear mm 2

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3 Brake rotor diam‐ 288
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Brake rotor, mm 25
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Brake rotor, mm 22
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4 Brake caliper, diam‐ 57
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mm
3. Technical Data 3
Front Brakes PC57 (16”)

Item PR Number 1ZA/1ZD/1ZB
1 Brake caliper PC57 (16”)
2 Brake pad, mm 14
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Front Brakes C60 (17”)
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piston eter in
mm

Front Brakes PC60 (17”):

Item PR Number 1LJ
1 Brake Caliper PC60 (17”)
2 Brake pad, mm 14
thickness
limit without
backing plate
3 Brake Rotor diam‐ 340
eter in
mm
Brake rotor, mm 30
thickness
Brake rotor, mm 27
wear limit
piston eter in
mm
3.1.3 Rear Brakes

Rear Brakes - Bosch Multi-link Rear Axle
Item PR Number 1KS/1KT
1 Brake caliper Bosch
2 Brake pad, mm 11
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3. Technical Data 5
Rear Brakes - PC 38 HRA Multi-Link Rear Axle

Item PR Number 1KS/1KT
1 Brake Caliper PC 38 HRA
2 Brake pad, mm 11
thickness with‐
out backing
plate
limit without
backing plate
eter in
mm
Brake rotor, mm 10
thickness
Brake rotor, mm 8
wear limit
piston eter in
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limit without
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Rear Brakes - CL 38 (15”) Torsion Beam Rear Suspension AG. Volkswagen AG d

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1 Brake Caliper CI 38 (15”)
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Rear Brakes - CL 38 HRA Torsion Beam Rear Suspension

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backing plate
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Brake rotor, mm 10
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Brake rotor, mm 8
wear limit
piston eter in
mm
3. Technical Data 7
Rear Brakes - C 38 Torsion Beam Rear Suspension

Item PR Number 1KD
1 Brake Caliper C 38
2 Brake pad, mm 11
thickness
limit without
backing plate
eter in
mm
Brake rotor, mm 10
thickness
Brake rotor, mm 8
wear limit
piston eter in
mm
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4 Brakes Inspection
⇒ “4.1 General Information”, page 9
⇒ “4.2 Front Wheel Drive Vehicles, Checking”, page 9
4.1 General Information

♦ The testing takes place on a test stand.
♦ During testing, manual transmission vehicles must be placed
in neutral and automatic transmission vehicles placed in »N«.
olkswagen AG
en AG. V
♦ Always follow the instructions
olks provided by the test stand
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The brake control systems do not function when the ignition is off.
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The brake test is to be performed on a one-axle roller test stand.
spec
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Do not exceed a test speed of 6 km/h (4 mph).
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Volkswagen approved test stands meet these requirements.
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4. Brakes Inspection 9
45 – Antilock Brake System

1 General Information
⇒ “1.1 ABS Repair Instructions”, page 10
1.1 ABS Repair Instructions

The ABS brake system is divided diagonally (two circuits). The
vacuum brake servo unit boosts the brakes pneumatically.
Models with ABS do not have a mechanical brake pressure reg‐
ulator. A specially coordinated software program inside the ABS
Control Module - J104- determines brake pressure allocation at
the rear axle.
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10 Rep. Gr.45 - Antilock Brake System

Note
ABS malfunctions do not affect the brake system and the booster.
Conventional brake system stays operative even without ABS. A
change in braking behavior should be checked. When the ABS
indicator lamp is lit up, the rear wheels may lock prematurely dur‐
ing braking! n AG. Volkswagen AG age does
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1 - ABS Hydraulic Unit -auN55-
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and ABS Control Module - J104- ra
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2 - Brake Booster
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The ABS Hydraulic Unit - N55- and ABS Control Module - J104-
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are one unit. Separation can only be performed when removed
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from vehicle. The hydraulic pump may also not be separated from
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the ABS Hydraulic Unit - N55- .
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Anti-Lock Braking System (ABS) Repair Information
spec
es, in part or in w
♦ Before carrying out repair work on the ABS, determine the
t to the co
cause of damage as well as the control module code using
“Guided Fault Finding”.
rrectness of i
“Guided Fault Finding” is performed. Refer to Vehicle Diagnostic
Tester .
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♦ Disconnect the battery ground cable when the ignition is

switched off.
nform
ercia
♦ Before welding with an electric welding tool, observe the in‐

m
a
com
ti
formation found here ⇒ General Information; Body Repairs,
on in
Body Collision Repair .
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♦ When handling brake fluid, observe the relevant safety pre‐

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cautions and notes.

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♦ After finishing any work that required opening the brake sys‐
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Unit - VAS5234- . p by
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♦ During the final road test, make sure a controlled braking ma‐ Prote AG.
neuver is performed at least one time (pulsing must be felt in
brake pedal).
♦ It is necessary to maintain a high level of cleanliness when
working on the ABS system.
♦ Do not use fluid containing mineral oils, for example oils,
grease, etc.
♦ Thoroughly clean all connection points and their surrounding
areas before loosening. However, do not use aggressive
cleaning agents such as brake cleaner, gasoline, thinners or
similar compounds.
♦ Place the removed parts on a clean surface and cover them.
♦ Carefully cover or seal opened components if the repair is not
performed immediately. (Use plugs from repair set 1 H0 698
311 A)
♦ Only use lint-free cloths.
♦ Remove the replacement parts from their packaging just prior
to installing them.
♦ Only use parts in their original packaging.
♦ Do not work with compressed air when the system is open.
♦ Do not move the vehicle.
1. General Information 11
♦ The valve coils in the ABS Control Module - J104- cannot be

readjusted.
♦ The valve coils in the ABS Control Module - J104- cannot be
replaced.
♦ The pressure sensor must not be changed or damaged.
♦ The pressure sensor cannot be replaced.
♦ The sensor housing must not be under any mechanical load.
♦ No measurements can be taken at the contacts inside the ABS
Control Module - J104- .
♦ No measurements can be taken at the contacts inside the ABS
Hydraulic Unit - N55- .
♦ The valve bodies inside the ABS Hydraulic Unit - N55- must
not be damaged or bent.
♦ The contacts cannot be replaced.
♦ Using contact sprays on the contacts and pressure sensor are
not permitted.
♦ No foreign objects may be between the ABS Control Module AG. Volkswagen
- J104- and the ABS Hydraulic Unit - N55- . lksw
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♦ The ABS Control Module - J104- may be briefly
ris
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db to a ran
tee
maximum temperature of 95 °C (203 °F) when
ut painting.
ho
or
sa ac
♦ The ABS Control Module - J104- may be sexposed to a tem‐
ce
le
perature of 85 °C (185 °F) for approximately two hours.

un
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♦ Make sure that brake fluid cannot get into the connectors.
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2 Component Location Overview

⇒ “2.1 Component Location Overview - ABS/ESP”, page 13
2.1 Component Location Overview - ABS/ESP
1 - ABS Control Module - J104-

❑ Component location: on
the ABS Hydraulic Unit -
N55- in the engine com‐
partment on the front
passenger side.
❑ Do not disconnect the
connector before suc‐
cessfully completing On
Board Diagnostic
(OBD). Switch ignition
off before separating
connector
Components:
♦ Electromechanical Parking
Brake Control Module -
J540-
♦ Transverse Acceleration
Sensor - G200-
♦ Rotation Rate Sensor -
G202-
♦ Longitudinal Acceleration
Sensor - G251- (depending AG. Volkswagen AG d
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♦ The components cannot be rise
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❑ Removing and instal‐ s
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ling. Refer to
un
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⇒ “3.2.1 ABS Control

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Module J104 / ABS Hy‐

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ab
draulic Unit N55 , Gaso‐

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and Installing”,
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page 17 .
spec
2 - ABS Hydraulic Unit - N55-

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❑ Component location: in
the engine compartment on the front passenger side
rrectne
The ABS Hydraulic Unit - N55- consists of the following components:

♦ ABS Hydraulic Pump - V64-
ss o
♦ Brake Pressure Sensor 1 - G201-

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♦ Valve block (contains inlet and outlet valves)

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❑ The ABS Hydraulic Pump - V64- and valve block must not be separated from one another.
o
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or
❑ Removing and installing. Refer to

thi
e
⇒ “3.2.1 ABS Control Module J104 / ABS Hydraulic Unit N55 , Gasoline Engine, Removing and Instal‐
t
sd
iva
ling”, page 17 .
pr
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3 - Brake Pad Wear Indicator Lamp - K32-

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4 - ABS Indicator Lamp - K47-
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❑ Component location: inside the instrument cluster
AG.
2. Component Location Overview 13

5 - ASR/ESP Indicator Lamp - K155-

6 - Brake System Indicator Lamp - K118-
7 - Brake Lamp Switch - F-
❑ Installed location: on the master brake cylinder
❑ Removing and installing
8 - ASR/ESP Button - E256-
❑ Two versions, two component locations:
gen AG
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♦ via the functioning surfaces
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a
❑ ASR/ESP Button - E256- in the center console removing and installing. Refer to ⇒ Electrical Equipment;
ss c
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Rep. Gr. 96 ; Controls; ASR/ESP Button - E256- , Removing and Installing .

nl
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9 - Diagnostic Connection
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❑ Component location: driver side footwell cover
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10 - Steering Angle Sensor - G85-
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hole
❑ Installed location: inside the steering gear
spec
es, in part or in w
❑ The Steering Angle Sensor - G85- cannot be changed separately.
t to the co
❑ Steering removing and installing. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 48 ; Steering Gear;
Steering Gear, Removing and Installing .
rrectness of i
11 - Right/Left Front ABS Wheel Speed Sensor -G45- / -G47-
l purpos
❑ Removing and installing. Refer to ⇒ “4.1 Overview - Front Axle Speed Sensor”, page 35 .
12 - Wheel Hub with Wheel Bearing nf
ercia
❑ The ABS sensor ring is installed in the wheel bearing

rm
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13 - Right/Left Rear ABS Wheel Speed Sensor -G44- / -G46-

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❑ Removing and installing (FWD). Refer to ⇒ “4.2 Overview - Rear Axle Speed Sensor”, page 36 .
thi
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14 - Wheel Hub with Wheel Bearing

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❑ The ABS sensor ring is installed in the wheel bearing

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3 Control Module and Hydraulic Unit

⇒ “3.1 Overview - Control Module and Hydraulic Unit”,
page 15
⇒ “3.2 ABS Control Module J104 / ABS Hydraulic Unit N55 , Re‐
moving and Installing”, page 17
⇒ “3.3 Control Module, Separating from Hydraulic Unit”,
page 31
⇒ “3.4 Control Module, Attaching to Hydraulic Unit”, page 32
⇒ “3.5 Brake Lines, Attaching to Hydraulic Unit”, page 33
3.1 Overview - Control Module and Hydraulic Unit
1 - ABS Control Module - J104-

❑ Removing and instal‐
ling. Refer to
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page 17 . se
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2 - ABS Hydraulic Unit - N55-
au
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un
ling. Refer to
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and Installing”,
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spec
page 17 .
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3 - TORX® Bolt
❑ 1. Step: Preliminary
tightening specification
rrectne
1 Nm to 1.5 Nm (to in‐

stall the seal)
ss
❑ 2. Step: final tightening

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specification: 2.5 Nm
inform
mer
❑ Install the new TORX®

atio
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bolt in two steps switch‐

o
ing back and forth.

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4 - Brake Line
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❑ 14 Nm
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❑ Identification: 5.25 mm
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diameter and tube fitting
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❑ To the right rear brake Prote
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agen
caliper
5 - Brake Line
❑ 14 Nm
❑ Identification: 5.25 mm diameter and tube fitting with a M10 x 1 thread
❑ To the left front brake caliper
6 - Brake Line
❑ 14 Nm
❑ To the right front brake caliper
3. Control Module and Hydraulic Unit 15

7 - Brake line
❑ 14 Nm
❑ To the left rear brake caliper
8 - Brake Line
❑ 14 Nm
❑ Identification: 6 mm diameter and tube fitting with a M12 x 1 thread
❑ Brake master cylinder/primary piston circuit to the ABS Hydraulic Unit - N55-
9 - Brake Line
❑ 14 Nm
❑ Identification: 6 mm diameter and tube fitting with a M12 x 1 thread
❑ Brake master cylinder/secondary piston circuit to the ABS Hydraulic Unit - N55-
10 - Brake Booster
❑ Removing and installing
11 - Bracket
12 - Bolt
❑ 8 Nm
13 - Rubber Buffer
14 - Heat Shield
For allocation. Refer to the Parts Catalog
15 - Hex Nut
❑ 20 Nm
16 - Bracket
17 - Hex Nut
❑ 20 Nm
AG. Volkswagen AG d
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Rep. Gr.45 - Antilock Brake System Prote AG.
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3.2 ABS Control Module - J104- / ABS Hy‐
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draulic Unit - N55- , Removing and In‐
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⇒ “3.2.1 ABS Control Module J104 / ABS Hydraulic Unit N55 ,
hole
spec
Gasoline Engine, Removing and Installing”, page 17
es, in part or in w
t to the co
⇒ “3.2.2 ABS Control Module and ABS Hydraulic Unit, Removing
and Installing”, page 21
rrectness of i
3.2.1 ABS Control Module - J104- / ABS Hy‐
draulic Unit - N55- , Gasoline Engine,
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Removing and Installing
nf
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Special tools and workshop equipment required
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♦ Torque Wrench 1331 5-50Nm - VAG1331-

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♦ Open Ring Spanner Insert - AF 11mm - VAG1410/6-
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♦ Torque Wrench - Universal Joint - VAG1410/7-

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♦ Mini Torque Wrench - VAS6854-

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♦ Brake Pedal Actuator - VAG1869/2- .
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♦ Torque Wrench - Assembly Tool - VAG1410/8-
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Plugs 5Q0 698 311
1 - M10 Plug
2 - M12 Plug
Installed Component Location

The ABS Control Module - J104- -1- is attached to the ABS Hy‐
draulic Unit - N55- and is located inside the engine compartment
on the right side.
Removing
WARNING
Do not bend the brake lines near the ABS Hydraulic Unit -
N55- !
– Read and note the present control module coding.

– If the vehicle has a coded radio, get the radio code from the
customer before beginning.
– Disconnect the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 ; Battery; Battery, Disconnecting and Connecting .
– If equipped, remove the engine cover. Refer to ⇒ Engine Me‐
chanical, Fuel Injection and Ignition; Rep. Gr. 10 ; Engine
Cover; Engine Cover, Removing and Installing .

Brake System - Edition
wage12.2015
e
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Vol t gu
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– If equipped, removeris
e the heat shield -1-.
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– Unclip the heat
ss
a shield -1- from the bracket -2- -arrow-. ra
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– Unclip the wire routing.

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– Push the lock washer downward in the direction of -arrow A-.
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– Release the locking mechanism in the direction of -arrow B-.

– Remove the connector -1-.
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– Install the Brake Pedal Actuator - VAG1869/2- .
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– Attach the bleeder bottle bleed hose -1- to the left front brake
caliper bleed valve.
– Open the bleed valve.

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– Attach the bleeder bottle bleed hose -1- torisethe left rear brake
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caliper bleed valve. autho eo
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– Push the brake pedal with the Brake Pedal Actuator -
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– Close left front and left rear bleeder valves.
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– Do not remove the Brake Pedal Actuator - VAG1869/2- .
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spec
es, in part or in w
t to the co
Note
Make sure no brake fluid gets onto contacts.
rrectness of i
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– Remove the cover from the bulkhead and unclip the brake line.
nform
ercia
– Label both brake lines -5 and 6-.

m
at
– Remove the brake lines -5 and 6- from the ABS Hydraulic Unit
om
io
- N55- .
n
c
in t
or
his
e
– Close brake lines and open connections using Sealing Plugs

at
do
riv
from the Repair Kit - 1H0 698 311 A- or with suitable plugs
p
cum
or
from the Engine Bung Set - VAS6122- .

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
– Label the remaining brake lines (brake caliper) -arrows- and

remove.

– Pull the ABS Control Module - J104- with the ABS Hydraulic
Unit - N55- upward from the shock absorber -arrow-.
Installing
Install in reverse order of removal. Note the following:
Note
♦ Remove the plugs on the new ABS Hydraulic Unit - N55- only
when installing the brake line.
♦ Brake fluid will leak out if the plugs are removed too early from
the ABS Hydraulic Unit - N55- . The system will then not have
sufficient brake fluid and will not adequately bled.
olkswagen AG
en AG. V
♦ Pay attention when installing the ABS Hydraulic Unit - N55-
olks
wag does
not
that the rubber bushings are not pushed out of the console.
ed
by
V gu
ara
ris nte
utho eo
– Before assembling the holder for the ABS - Hydraulic
ss
a Unit ra
c
N55- in the bracket, spray the rubber bushings with Silicone
ce
le
un
pt
Lubricant Spray - D 007 000 A2- .
an
d
itte
y li
erm
ab
– Install the brake lines carefully with the Torque Wrench - As‐
ility
ot p
sembly Tool - VAG1410/8- .
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
Tightening Sequence
o
n
c
i
or
n
– Remove the Brake Pedal Actuator - VAG1869/2- .
thi
te
sd
iva
o
r
– Bleed the brake system. Refer to

p
cum
r
fo
⇒ “6 Hydraulic System”, page 132 .

en
ng
t.
yi Co
op
– Enter radio code. C py
t. rig
gh ht
yri by
– Code ABS Control Module - J104- using the Vehicle Diagnos‐ cop Vo
by lksw
tic Tester in "Guided Fault Finding". cted agen
Prote AG.
A Steering Angle Sensor - G85- , Transverse Acceleration Sensor

- G200- , Longitudinal Acceleration Sensor - G251- and Brake
Pressure Sensor 1 - G201- basic setting must be done.
Tightening Specifications

Special Tool Assembly for Tightening the Brake Lines

♦ Refer to
page 15
♦ Refer to ⇒ Engine Mechanical, Fuel Injection and Ignition;
Rep. Gr. 10 ; Engine Cover; Engine Cover, Removing and
Installing .
Rep. Gr. 26 ; Exhaust Pipes/Mufflers; Overview - Muffler .
♦ Refer to ⇒ “1.1 Overview - Front Brake Caliper”, page 97
♦ Refer to ⇒ “2.1 Overview - Rear Brake Caliper”, page 100
3.2.2 ABS Control Module and ABS Hydraulic

Unit, Removing and Installing
Plugs 5Q0 698 311
1 - M10 Plug
2 - M12 Plug
Installed ComponentgLocation
en AG. V
olkswagen AG
a does
ksw not
y Vol gu
The ABS rControl
ise
d b
Module - J104- is attached to the ABS
ara
nte Hydraulic
Unit - N55-
utho -1- and is located inside the engine compartment
eo
ra
on
the right
ss a side. c
ce
e
nl
Removing
pt
du
an
itte
y li
erm
ab
WARNING
ility
ot p
wit
, is n
h re
hole
N55- !
spec
es, in part or in w
t to the co

rrectness of i
l purpos

nform
ercia
– Remove the engine cover. Refer to ⇒ Engine Mechanical,

m
at
Fuel Injection and Ignition; Rep. Gr. 10 ; Engine Cover; Engine

om
ion
Cover, Removing and Installing .

c
in t
or
his
te
Diesel Engine with Particulate Filter

a
do
priv
cum
or
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.

f
en
g
Gr. 66 ; Noise Insulation; Overview - Noise Insulation .

n
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

wage
e
ks s no
Vol t gu
by a
– Remove the drive axleriseheat shield if equipped -arrows-. Refer rante
d
to ⇒ Suspension, Wheels,
ut
ho Steering; Rep. Gr. 40 ; Drive Axle; eo
ra
Drive Axle Heat sShield,
sa Removing and Installing . c
ce
e
nl
– Remove the front exhaust pipe. Refer to ⇒ Rep. Gr. 26 ; Ex‐
pt
du
an
haust Pipes/Mufflers; Front Exhaust Pipe, Removing and In‐
itte
y li
erm
stalling .
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
– Disconnect the connector -1-.
l purpos
– Loosen the clamping sleeve -2- and slide it toward the rear.
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
– Remove the bolts -1-. cted agen
Prote AG.
– Loosen the bolt -2- and remove the clamp.

– Remove the front exhaust pipe.
For Vehicles with a Parking/Auxiliary Heater

– Remove the front exhaust pipe. Refer to ⇒ Engine Mechani‐
cal, Fuel Injection and Ignition; Rep. Gr. 26 ; Exhaust Pipes/
Mufflers; Muffler, Removing and Installing .
– Remove both nuts -arrows- from the coolant line bracket -1-
on the longitudinal member and the bracket.
– Pull the bracket from the pins and pull the coolant line as far
downward as possible.

Continuation for All Vehicles

– If equipped, remove the heat shield -1-.
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
– Unclip the heat shield -1- from the bracket -2- -arrow-.
ility
ot p
wit
– On vehicles with heat shield, remove heat shield -item 14-
, is n
h re
⇒ Item 14 (page 16) .
hole
spec
es, in part or in w
t to the co
– Push the lock washer downward in the direction of -arrow A-.
– Release the locking mechanism in the direction of -arrow B-.
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.

– Attach the bleeder bottle bleed hose -1- to the left rear brake
– Push the brake pedal with the Brake Pedal Actuator -
VAG1869/2- at least 60 mm.
– Place a lint-free cloth under the ABS Control Module - J104- agen
AG. Volkswagen AG d
oes
and the ABS Hydraulic Unit - N55- . Volksw not
gu
d by ara
ise nte
or eo
h
ut ra
Note ss a c
ce
e
nl
pt
du
Make sure no brake fluid gets onto contacts.
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
– Label both brake lines -5 and 6-.
hole
spec
es, in part or in w
– Remove the brake lines -5 and 6- from the ABS Hydraulic Unit
t to the co
- N55- .
– Seal off the brake lines and the threaded holes right away with
the plugs from repair kit 1H0 698 311 A.
rrectness of i
– Mark, unfasten and plug the remaining brake lines (brake cal‐
l purpos
ipers).
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
a
– Pull the ABS Hydraulic Unit - N55- with the ABS Control Mod‐
iv
o
r
rp
cu
ule - J104- upward from the shock absorber -arrow-.
o
m
f
en
ng
t.
yi
– Place the ABS Hydraulic Unit - N55- with the ABS Control
Co
op py
Module - J104- at the bottom of the engine compartment. t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted
Caution
agen
Prote AG.
Set aside the ABS Hydraulic Unit - N55- with the ABS Control
Module - J104- so that it cannot fall down.
– Raise the vehicle.

For Vehicles with a Parking/Auxiliary Heater

– Remove the bracket in the vehicle from the ABS Hydraulic Unit
- N55- -arrows-.
Continuation for All Vehicles lkswage es n
o ot g
yV ua
– Guide the ABS Hydraulic Unit - riN55-
se
d b
from the vehicle. ran
tee
tho
or
Installing au ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
Note
ility
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h re
♦ Remove the plugs on the new ABS Hydraulic Unit - N55- only
hole
spec
when installing the brake line.
es, in part or in w
t to the co
♦ Brake fluid will leak out if the plugs are removed too early from
the ABS Hydraulic Unit - N55- . The system will then not have
sufficient brake fluid and will not adequately bled.
rrectness of i
♦ Pay attention when installing the ABS Hydraulic Unit - N55-
that the rubber bushings are not pushed out of the console.
l purpos
– Before assembling the holder for the ABS Hydraulic Unit -
nform
ercia

m
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
co lksw
by
cted agen
Prote AG.
Brake Line Tightening Sequence

– Enter radio code.
– Code the ABS Control Module - J104- using the Vehicle Di‐
agnostic Tester .


♦ Refer to
page 15
Rep. Gr. 26 ; Exhaust Pipes/Mufflers; Overview - Muffler .
♦ Refer to ⇒ Body Exterior; Rep. Gr. 66 ; Noise Insulation;
Overview - Noise Insulation .
Rep. Gr. 26 ; Exhaust Pipes/Mufflers; Muffler, Removing and
Installing .
Rep. Gr. 10 ; Subframe Mount; Overview - Subframe Mount .
Installing .
♦ Front bleeder valve. Refer to . Volkswagen AG
⇒ “1.1 Overview - Front Brake Caliper”, page 97
ksw
.agen AG does
n ol ot g
yV ua
♦ Rear bleeder valves. Refer to ed
b ran
ris
⇒ “2.1 Overview - Rear Brake Caliper”,
ut
h page 100
o tee
or
a ac
ss
ce
3.2.3 ABS Control Module and ABS Hydraulic
le
un
pt
an
d
Unit, Removing and Installing

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
♦ Brake Pedal Actuator - VAG1869/2- . rrectness of i
l purpos

nform
ercia
Plug assembly part number 5Q0 698 311

m
1 - M10 plug
a
com
tion in
2 - M12 plug
r
te o
thi
s
iva
Removing
do
r
rp
cum
fo
Component location:
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

The control module is bolted to the hydraulic unit -1- and is located
at right in the engine compartment.
WARNING
N55- !

olkswagen AG
– If the vehicle has a coded radio, get the radio code agfrom
en AG.the
V
does
ksw
customer before beginning. by
Vol not
gu
d ara
ise nte
– Disconnect the battery. Refer to ⇒ Electrical
thor Equipment; Rep. eo
Gr. 27 ; Battery; Battery, Disconnecting
s au and Connecting . ra
c
s
ce
le
– Remove the engine cover.

un
pt
an
d
itte
y li
– Remove the noise insulation. Refer to ⇒ Body Exterior; Rep.
rm
ab
Gr. 66 ; Noise Insulation; Overview - Noise Insulation .
pe
ility
ot
wit
– Remove the front exhaust pipe. Refer to ⇒ Rep. Gr. 26 ; Ex‐
, is n
h re
haust Pipes/Mufflers; Front Exhaust Pipe, Removing and In‐
hole
spec
stalling .
es, in part or in w
t to the co
– Disconnect the connector -1-.
– Loosen the clamping sleeve -2- and slide it toward the rear.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
op
– Remove the bolts -1-. C py
t. rig
gh ht
yri by
– Loosen the bolt -2- and the clamp. cop Vo
by lksw
cted agen
Prote
– Remove the front exhaust pipe.
AG.
– Remove the right driveshaft. Refer to ⇒ Suspension, Wheels,

Steering; Rep. Gr. 40 ; Driveshaft; Driveshaft, Removing and
Installing
– Pivot the suspension strut to the rear and lock.
– On vehicles with heat shield, remove heat shield.

– Press the securing clip down -arrow A-.
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
ce
e
nl
pt
du
an
– Disconnect the connector -arrow B-.
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
ercia

m
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

– Attach the bleeder bottle bleed hose -1- to the left rear brake
caliper bleed valve. en AG. Volkswagen AG
ag does
ksw not
Vol valve.
– Open the bleed gu
by d ara
ise nte
– Pushutthe
ho brake pedal with the Brake
r
Pedal Actuator e o-
VAG1869/2-
ss
a at least 60 mm. ra
c
ce
le

un
pt
an
d
itte
y li
rm
ab
pe
ility
– Place sufficient lint-free cloths under the control module and
ot
wit
, is n
hydraulic unit.
h re
hole
spec
es, in part or in w
Note
t to the co
Make sure that brake fluid does not come in contact with the ter‐
minals.
rrectness of i
l purpos
– First, mark both brake lines from master cylinder and remove
nform
ercia
from the hydraulic unit.

m
a
com
t
– Seal the threaded holes immediately with plugs from the as‐
ion in
sembly part set part number 5Q0 698 311.
r
te o
thi
s
iva
– Mark, remaining brake lines (brake calipers), unfasten and

do
r
rp
plug the threaded holes.

um
fo
en
ng
t.
yi Co
op
– Lift the hydraulic unit with control module up and out of the
C py
t. rig
dampers -arrow-.
gh ht
pyri by
Vo
o
by c lksw
– Place the hydraulic unit with the control module carefully below
Prote
cted AG.
agen
in the engine compartment.
Caution
Set aside the ABS Hydraulic Unit - N55- with the ABS Control
Module - J104- so that it cannot fall down.
– Remove the bracket in the vehicle from the hydraulic unit

-arrows-.
– Pivot the suspension strut -1- to the side and toward the rear.
Lock it in this position with a wooden block -2-.
– Carefully guide the hydraulic unit with the control module
downward.
– Carefully place the hydraulic unit with the control module at
the bottom of the engine compartment.
Note
Position the ABS Hydraulic Unit - N55- with the ABS Control Mod‐
ule - J104- so that it cannot fall down.

– Guide out the hydraulic unit -3- out of the vehicle through the
wheel housing.
Installing
Note
♦ Do not remove sealing plugs at new hydraulic unit until the

corresponding brake line is about to be installed.
♦ If the sealing plugs are removedwatoo
genearly,
AG. Volbrake
kswagenfluid
AG dcan
oe es‐
cape and unit may not be sufficiently
yV
olks filled or adequatelysbled.
not
gu b ara
ed
♦ When installing the hydraulic
tho
ris unit, make sure the damper rub‐ nte
e
ber is not pushed sout
au of the console.
or
ac
s
ce
le
un
pt
– Before assembling the holder for the ABS Hydraulic Unit -
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
– Install in reverse order of removal.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
Brake Line Tightening Sequence

rp
cum
fo
en
ng

t.
yi Co
Cop py
. rig
t
gh ht
yri by
⇒ “6.2 Hydraulic System, Standard Bleeding”, page 132 . cop Vo
by lksw
cted agen
Prote
– Enter radio code.
AG.
– Code the ABS Control Module - J104- using the Vehicle Di‐
agnostic Tester .


♦ Refer to
page 15
♦ Battery. Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Bat‐
tery; Overview - Battery .
♦ Noise insulation bolts. Refer to ⇒ Body Exterior; Rep. Gr.Vo66 ;
lkswagen AG
Noise Insulation; Overview - Noise Insulation .swagen AG. does
k not
y Vol gu
♦ Front exhaust pipe. Refer to ⇒ Rep. Gr. d b26 ; Exhaust Pipes/ ara
ise nte
Mufflers; Front Exhaust Pipe, Removing
tho
r and Installing . eo
au ra
c
♦ Pendulum support. Refer to ⇒ Engine
ss Mechanical, Fuel In‐
ce
e
jection and Ignition; Rep. Gr. 10 ; Subframe Mount; Overview
nl
pt
du
an
- Subframe Mount .
itte
y li
erm
ab
♦ Driveshaft. Refer to ⇒ Suspension, Wheels, Steering; Rep.
ility
ot p
Gr. 40 ; Drive Axle; Overview - Drive Axle .
wit
, is n
h re
♦ Lower control arm. Refer to ⇒ Suspension, Wheels, Steering;
hole
spec
Rep. Gr. 40 ; Lower Control Arm and Ball Joint; Overview -
es, in part or in w
Lower Control Arm and Ball Joint .
t to the co
♦ Front bleeder valve. Refer to
⇒ “1.1 Overview - Front Brake Caliper”, page 97 .
rrectness of i
♦ Rear bleeder valves. Refer to
l purpos
⇒ “2.1 Overview - Rear Brake Caliper”, page 100
3.3 Control Module, Separating from Hy‐
nform
ercia
draulic Unit
m
at
om
ion
c
in t
or
his
ate
♦ ESD Work Surface - VAS6613-
do
priv
cum
or
♦ TORX® Insert T25

f
en
ng
t.
yi Co
op py
♦ If the ABS Control Module - J104- is faulty, then the control t. C rig
gh ht
module is to be separated from the ABS Hydraulic Unit - N55- yri
p by
o Vo
and only the control module replaced.
c by lksw
cted agen
Prote AG.
♦ If the ABS Hydraulic Unit - N55- is faulty, then replace the ABS
Hydraulic Unit - N55- together with the ABS Control Module -
J104- .
♦ To separate the ABS Control Module - J104- and the ABS Hy‐
draulic Unit - N55- the unit must be removed.
WARNING
♦ The return flow pump may also not be separated from the
ABS Hydraulic Unit - N55- .
♦ The circuit board is exposed when the ABS Control Mod‐
ule - J104- is removed.
♦ Protect the ABS Control Module - J104- from moisture and
dirt particles from getting inside.
♦ Avoid build-up of static electricity!
This build-up of static electricity can lead to malfunctions when

contacting electrical components.
– Touch a grounded object, before working on electrical equip‐
ment ESD Work Surface - VAS6613- . Do not touch directly
on the connector terminals or the electrical components.

– Place the ABS Hydraulic Unit - N55- with the ABS Control
Module - J104- on the ESD Work Surface - VAS6613- .
– Remove the three TORX® bolts from the ABS Control Module
- J104- and set aside immediately (risk of confusing them with
the new TORX® bolts).
– Place the ABS Hydraulic Unit - N55-swwith
agen the ABS Control
AG. Volkswagen AG d
oes
Module - J104- upward on the ESD
by
V Work Surface - VAS6613- . ot gu
olk n
ara
ed nte
ris
– Remove the ABS ControlthoModule - J104- from the ABS Hy‐ e or
draulic Unit - N55- without
s au tilting it. ac
s
ce
le
– Cover ABS Control Module - J104- solenoid coils with a lint-

un
pt
free cloth.
an
d
itte
y li
rm
ab
– Clean the ABS Hydraulic Unit - N55- sealing surface using
pe
ility
mineral spirits and a lint-free cloth.
ot
wit
, is n
h re
The ABS Hydraulic Unit - N55- sealing surface must not be
hole
spec
worked with a file, metal scraper, sand paper or similar.
es, in part or in w
t to the co
If the ABS Hydraulic Unit - N55- sealing surface is damaged (for
example through grooves or scrapes) the ABS Hydraulic Unit -
N55- must be replaced with the ABS Control Module - J104- .
rrectness of i
The seal on the ABS Control Module - J104- must not be pulled
l purpos
out or raised up.

The seal on the ABS Control Module - J104- cannot be replaced.
nform
mercia
a
com
tion in
r
te o
thi
3.4 Control Module, Attaching to Hydraulic
s
iva
do
r
rp
Unit
um
fo
en
ng
t.
yi Co
Special tools and workshop equipment required t. Cop py
rig
gh ht
yri
♦ Torque Screwdriver - VAG1624- p by
o Vo
by c lksw
cted agen
♦ ESD Work Surface - VAS6613- Prote AG.
♦ TORX® insert T25
WARNING
Excessive shaking (for example, dropping, impact) can dam‐

age the ABS Control Module - J104- . Do not use the ABS
Control Module - J104- again if this happens.
• Surface must be cleaned before assembling.

– Place the ABS Control Module - J104- on the ABS Hydraulic
Unit - N55- without tilting it.
– Tighten the ABS Hydraulic Unit - N55- and the ABS Control
Module - J104- with the supplied new TORX® bolts in two
steps switching back and forth to the tightening specification.

Note
♦ The ABS Hydraulic Unit - N55- threads cannot be re-cut to

secure the ABS Control Module - J104- .
♦ If the threads are damaged, the ABS Hydraulic Unit - N55-
must be replaced.
♦ If the bolts are difficult to remove by hand or cannot be tight‐
ened to the tightening specification then the threads are dam‐
aged.
Tightening Specification
♦ Refer to
page 15
Note
♦ A new ABS Control Module - J104- can be installed on an old

ABS Hydraulic Unit - N55- three times, maximum. This as‐
sures the elastic seal will not leak.
♦ A used ABS Control Module - J104- may not be installed a
second time.
3.5 Brake Lines, Attaching to Hydraulic Unit

On Tandem Master Brake Cylinder: AG. Volkswagen AG d
agen oes
lksw not
A - Master Brake Cylinder Primary Piston Circuit to the dABS by
V Hy‐
o gu
ara
draulic Unit - N55- . orise nte
eo
h
ut ra
- Identification: 6 mm diameter and tube fitting with
ss a a M12 x 1 c
thread
ce
le
un
pt
an
d
B - Master Brake Cylinder Secondary Piston Circuit to the ABS

itte
y li
rm
ab
pe
ility
ot
- Identification: 6 mm diameter and tube fitting with a M12 x 1
wit
, is n
thread
h re
hole
spec
1 - ABS Hydraulic Unit - N55- to the Left Front Brake Caliper
es, in part or in w
3 - ABS Hydraulic Unit - N55- to the Left Rear Brake Caliper t to the co
4 - ABS Hydraulic Unit - N55- to the Right Rear Brake Caliper
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

Tightening Sequence:
1 - ABS Hydraulic Unit - N55- to the Right Rear Brake Caliper
- Identification: 5.25 mm diameter and tube fitting with a M12 x 1
short thread
2 - ABS Hydraulic Unit - N55- to the Left Front Brake Caliper
thread
3 - ABS Hydraulic Unit - N55- to the Right Front Brake Caliper
short thread
4 - ABS Hydraulic Unit - N55- to the Left Rear Brake Caliper
thread
5 - ABS Hydraulic Unit - N55- to the Master Brake Cylinder Sec‐
ondary Piston Circuit
thread
6 - ABS Hydraulic Unit - N55- to the Master Brake Cylinder Pri‐
mary Piston Circuit
thread
Tightening Specification AG. Volkswagen AG d
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4 Sensors
⇒ “4.1 Overview - Front Axle Speed Sensor”, page 35
⇒ “4.2 Overview - Rear Axle Speed Sensor”, page 36
⇒ “4.3 Right/Left Front ABS Wheel Speed Sensor G45 / G47 ,
Removing and Installing”, page 37
⇒ “4.4 Right/Left Rear gABS
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⇒ “4.6 Steering Angle Sensor G85 , Removing and Installing”,

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⇒ “4.7 ABS Sensor Ring, Checking”, page 39
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G47- / -G45-
❑ Left Front ABS Wheel
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Speed Sensor - G47- /
Right Front ABS Wheel
Speed Sensor - G45- ss o
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ling. Refer to
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mer
⇒ “4.3 Right/Left Front

atio
ABS Wheel Speed Sen‐

om
sor G45 / G47 , Remov‐

c
i
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ing and Installing”, page

thi
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37 .
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2 - Bolt
❑ 8 Nm
3 - Drive Axle
❑ Overview. Refer to ⇒
Suspension, Wheels,
Steering; Rep. Gr. 40 ;
Drive Axle; Overview -
Drive Axle .
ling. Refer to ⇒ Suspen‐
sion, Wheels, Steering;
Rep. Gr. 40 ; Drive Axle;
Drive Axle, Removing
and Installing .
4 - Wheel Hub with Wheel
Bearing Unit
❑ The ABS sensor ring is
integrated in the wheel bearing unit
❑ Removing and installing. Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 40 ; Wheel Bearing; Wheel
Bearing Unit, Removing and Installing .
4. Sensors 35
4.2 Overview - Rear Axle Speed Sensor

⇒ “4.2.1 Overview - Rear Axle Speed Sensor, FWD”, page 36
⇒ “4.2.2 Overview - Rear Axle Speed Sensor, AWD”, page 37
4.2.1 Overview - Rear Axle

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❑ Removing and Instal‐
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⇒ “4.4 Right/Left Rear

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❑ Clean the inner surface
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❑ Coat the hole with Hot
Bolt Paste - G 052 112
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A3- .
s
2 - Bolt
s o
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❑ 8 Nm
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4.2.2 Overview - Rear Axle Speed Sensor, AWD
1 - ABS Speed Sensor

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3 - Driveshaft
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❑ Overview. Refer to ⇒
t to the co
Suspension, Wheels,
Steering; Rep. Gr. 42 ;
Overview - Driveshaft .
rrectne
s
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Rep. Gr. 42 ; Driveshaft;
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Driveshaft, Removing
form
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and Installing .
atio
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Ring, Checking”,
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page 39 .
❑ Removing and Instal‐
Rep. Gr. 42 ; Wheel
Bearing, Trailing Arm;
Wheel Bearing Unit, Removing and Installing .
4.3 Right/Left Front ABS Wheel Speed Sen‐

sor -G45- / -G47- , Removing and In‐
stalling
Note
The example describes the removal and installation of the left

front ABS wheel speed sensor. The removal and installation of
the right front ABS wheel speed sensor is identical.
Removing
4. Sensors 37
– Disconnect the connector -3- from the wheel speed sensor

-1-.
– Remove the bolt -2- and pull the wheel speed sensor -1- from
the wheel bearing housing.
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sensor
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♦ Refer to
h re
⇒ “4.1 Overview - Front Axle Speed Sensor”, page 35 hole
spec
es, in part or in w
t to the co
rrectness of i
4.4 Right/Left Rear ABS Wheel Speed Sen‐
l purpos
sor -G44- / -G46- , Removing and In‐
nform
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Wheel Speed Sensor -1-
Removing
– Disconnect the connector -2- from the wheel speed sensor.
– Remove bolt -1-, and remove the wheel speed sensor from the
wheel bearing housing.
Installing
– Clean the inner surface of the opening before inserting the
sensor
– Coat the hole with Hot Bolt Paste - G 052 112 A3- .
♦ Refer to
⇒ “4.2.1 Overview - Rear Axle Speed Sensor, FWD”,
page 36

4.5 ESP Sensor Unit - G419- , Removing

and Installing
The Transverse Acceleration Sensor - G200- , the Rotation Rate
Sensor - G202- and the Longitudinal Acceleration Sensor - G251-
are installed together with the Electromechanical Parking Brake
Control Module - J540- in the ABS Control Module - J104- .
The components cannot be replaced individually.
– ABS Control Module - J104- , removing and installing. Refer
to
⇒ “3.2 ABS Control Module J104 / ABS Hydraulic Unit N55 ,
Removing and Installing”, page 17 .
4.6 Steering Angle Sensor - G85- , Remov‐

ing and Installing
The Steering Angle Sensor - G85- is installed in the steering gear.
The Steering Angle Sensor - G85- cannot be replaced separately.
– Remove the steering. Refer to ⇒ Suspension, Wheels, Steer‐
ing; Rep. Gr. 48 ; Steering Gear; Steering Gear, Removing
and Installing .
4.7 ABS Sensor Ring, Checking

♦ Gauge - Sender Wheel - T10473-
Procedure
• The wheel bearing unit is removed.
– Check the entire circumference of the ABS sensor ring -2- with
the Gauge - Sender Wheel - T10473- as shown.
1 - Wheel Bearing Unit AG. Volkswagen AG d
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2 - Seal with integrated ABS Sensor Ring olksw not
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4. Sensors 39
ABS sensor ring test diagram.

A - ABS Sensor Ring is OK
B - ABS Sensor Ring is Faulty
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5 Special Tools
Special tools and workshop

equipment required
♦ Torque Wrench 1331
5-50Nm - VAG1331-
♦ Open Ring Spanner Insert -
AF 11mm - VAG1410/6-
♦ Torque Wrench - Universal agen
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Joint - VAG1410/7- olksw not
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♦ Mini Torque Wrench - horis
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♦ Brake Pedal Actuator -
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♦ Gauge - Sender Wheel - T10473-
♦ Torque Wrench 1410 - VAG1410-
5. Special Tools 41
♦ Torque Screwdriver - VAG1624-
♦ ESD Work Surface - VAS6613-
AG. Volkswagen AG d
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46 – Mechanical Components
1 Front Brakes
⇒ “1.1 Overview - Front Brakes”, page 43
⇒ “1.2 Brake Pads, Removing and Installing”, page 45
⇒ “1.3 Brake Caliper, Removing and Installing”, page 47
⇒ “1.4 Brake Carrier, Removing and Installing”, page 49
⇒ “1.5 Brake Rotor, Removing and Installing”, page 51
⇒ “1.6 Brake Shield, Removing and Installing”, page 52
1.1 Overview - Front Brakes

⇒ “1.1.1 Overview - Front Brakes (PC57 and C60)”, page 43
1.1.1 Overview - Front Brakes (PC57 and

C60)
Note lkswage es n
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♦ After replacing brake pads, depress brake tpedal
horis firmly several tee
times with vehicle stationary so that thes abrake
u pads are prop‐ or
ac
erly seated in their normal operating position.
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♦ Use Brake Charger/Bleeder Unit - VAS5234- to extract brake
an
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fluid from brake fluid reservoir.
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♦ Install the Brake Pedal Actuator - VAG1869/2- to relieve pres‐
wit
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sure before removing a brake caliper or disconnecting a brake
h re
hose.
hole
spec
es, in part or in w
t to the co
rrectness of i
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1. Front Brakes 43
1 - Cover Plate
2 - Bolt
❑ 12 Nm
3 - Brake Rotor AG. Volkswagen AG d
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ce
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and brake carrier before
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4 - Bolt hole
spec
❑ 8 Nm
es, in part or in w
t to the co
5 - Brake Carrier
❑ Lightly grease the pad
guide surface with Lithi‐
rrectness of i
um Grease - G 052150
l purpos
A2- .
6 - Brake Pads
nform
ercia
❑ Thickness 14 mm with‐
m
out backing plate
a
com
tio
❑ Vehicles with front right
n in
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brake pad wear indica‐
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replaced separately.
❑ Wear limit: 2 mm without
backing plate
❑ Check the thickness. Refer to ⇒ Maintenance ; Booklet 36.1 ; Procedure Descriptions; Front and Rear
Brake Rotors, Checking Brake Pad Thickness and Condition .
❑ Replace in pairs
❑ Removing and installing. Refer to ⇒ “1.2 Brake Pads, Removing and Installing”, page 45 .
7 - Trim
❑ Vehicles with emblem
❑ For allocation. Refer to the Parts Catalog
8 - Brake Caliper
❑ Do not disconnect the brake hose when replacing a brake pad
❑ Removing and installing. Refer to ⇒ “1.3 Brake Caliper, Removing and Installing”, page 47 .
❑ Servicing. Refer to ⇒ “1.2 Brake Caliper Piston, Removing and Installing”, page 98 .
9 - Hex Bolt, Self-Locking
❑ 35 Nm
❑ Replace after removing
10 - Ribbed Bolt
❑ 200 Nm
❑ Clean if using again.
44 Rep. Gr.46 - Mechanical Components

11 - Wheel Bearing Housing

❑ Vehicles with fastened
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12 - Brakeut Hose
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❑ s35 Nm
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❑ Vehicles with ring connection and banjo bolt
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❑ Make sure it is installed in the correct position
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13 - Clip
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14 - Bracket
hole
spec
15 - Bolt
es, in part or in w
t to the co
❑ 8 Nm
rrectness of i
1.2 Brake Pads, Removing and Installing
l purpos
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ercia

m
at
♦ Piston Resetting Tool - T10145-
om
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This procedure contains mandatory replaceable parts. Refer

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Mandatory Replacement Parts cted agen
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♦ Hex Bolt, Self-Locking - Brake caliper to brake carrier

Removing
Note
When removing, mark brake pads that will be used again. Install
in the same position, otherwise braking effect will be uneven.
– Remove the wheels.

– Release and disconnect the brake pad wear indicator con‐
nector.
The brake pad wear indicator is installed at the front right.
1. Front Brakes 45
– Counterhold the guide pins and remove both screws from the
brake caliper.
– Remove the brake caliper -1- and secure with wire so that the
weight of the brake caliper does enot stress
n AG. Volkswor damage
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brake hose. olks
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– Remove the brake pads
ris
ed -2 and 3- from the brake carrier -4-.ran
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Do not blow brake system using compressed air, the dust pro‐
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es, in part or in w
– Always thoroughly clean contact surfaces for brake pads at

t to the co
brake carrier, remove corrosion.

– Clean the brake caliper.
rrectness of i
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Note
nf
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Use only appropriate solvents for cleaning brake caliper.

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– Press the piston back.

– Lightly grease the pad guide surface on the brake carrier with
lithium grease G 052150 A2.

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– Place the brake pads -1- and the springs -2- into the opening
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es, in part or in w
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– Counterhold the guide pins and attach the brake caliper to the
nform
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brake carrier with new self-locking screws.

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– Connect the brake pad wear indicator connector.
on in
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– Install the wheels.
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♦ Wheel bolts. Refer to ⇒ Suspension, Wheels, Steering; Rep.
op Vo
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Gr. 44 ; Wheels and Tires; Wheel Bolt Tightening Specifica‐ cted agen
Prote AG.
tions .
Note
♦ After replacing brake pads, depress brake pedal firmly several

times with vehicle stationary so that the brake pads are prop‐
♦ Check brake fluid level after replacing brake pad.
1.3 Brake Caliper, Removing and Installing

Caution

Mandatory Replacement Parts

♦ Hex Bolt, Self-Locking - Brake caliper to brake carrier
Note
Work procedure applies only for replacing or when performing

subsequent service work on brake caliper.
1. Front Brakes 47
Removing
– Remove the wheels.
– Disconnect the brake pad wear indicator connector.
– Attach the bleeder bottle bleed hose -1- to the brake caliper
bleed valve.
– Open the bleeder valve.
AG. Volkswagen AG d
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– Install the Brake Pedal Actuator - VAG1869/2- .utho eo
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– Close the bleed valve and remove the bleeder bottle. s
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pt
– Remove the brake hose.
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– Counterhold the guide pins and remove both bolts from the
brake caliper.
– Remove the brake caliper from the brake carrier.
Installing
• Piston is pressed back.
• Both brake pads and their springs fit into the opening in the
brake carrier.
– Place the brake caliper carefully on the brake carrier.
– Counterhold the guide pins and attach the brake caliper to the
brake carrier with new self-locking screws.
– Attach the brake hose to the brake caliper.
– Connect the brake pad wear indicator connector.
– Install the wheels.
– Before moving the vehicle, press the brake pedal firmly sev‐
eral times to seat the brake pads correctly in their operating
position.
– Check brake fluid level.
♦ Refer to
⇒ “1.1.1 Overview w-aFront
gen AGBrakes (PC57
. Volkswagen AG and C60)”, page 43
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or ;
a
Wheels and Tires; Wheel Bolt Tightening Specificationsc .
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properly sit in their respective position.

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♦ Check the brake fluid level.

rrectne
1.4 Brake Carrier, Removing and Installing

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stall in the same position, otherwise braking effect will be
Prote
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uneven.
♦ Do not open the brake hydraulic system when removing!
1. Front Brakes 49
– Loosen the wheel bolts.

– Remove the wheel.
– Remove brake pads. Refer to
⇒ “1.2 Brake Pads, Removing and Installing”, page 45 .
– Remove brake caliper and secure with wire so that the weight
of the brake caliper does not burden or damage the brake
hose.
– Unscrew the threaded connection -arrows- from the cover
plate -1-.
– Remove the brake carrier -1-.
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– Check brake fluid level. Prote AG.
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♦ Refer to ⇒ Suspension, Wheels, Steering; Rep. Gr. 44 ;
Wheels and Tires; Wheel Bolt Tightening Specifications .

1.5 Brake Rotor, Removing and Installing

♦ Torque Wrench 1783 - 2-10Nm - VAG1783-
Removing
Note
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⇒ “1.4 Brake Carrier, Removing and Installing”, page 49 .
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1. Front Brakes 51
– Remove the bolt -arrow-.

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♦ Replace on both sides of axle if worn (Rotors replaced in pairs
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1.6 Brake Shield, Removing and Installing



Removing
Note
uneven.

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⇒ “1.5 Brake Rotor, Removing and Installing”, page 51 .
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1. Front Brakes 53
– Unscrew the threaded connection -arrows- from the cover

plate -1-.
– Remove cover plate -1-.
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⇒ “2.3 Brake Caliper, Removing and Installing”, page 66
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⇒ “2.4 Brake Carrier, Removing and Installing”, page 72
⇒ “2.5 Brake Rotor, Removing and Installing”, page 74
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⇒ “2.6 Brake Shield, Removing and Installing”, page 76
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2.1 Overview - Rear Brakes
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♦ Use Brake Charger/Bleeder Unit - VAS5234- to extract brake fluid from brake fluid reservoir.
♦ Install the Brake Pedal Actuator - VAG1869/2- to relieve pressure before removing a brake caliper or dis‐
connecting a brake hose.
♦ After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake
pads are properly seated in their normal operating position.
2. Rear Brakes 55
1 - Bolt
❑ 8 Nm
2 - Bolt
❑ 90 Nm +90°
❑ Quantity: 2
3 - Wheel Speed Sensor
❑ Overview. Refer to
⇒ “4.2 Overview - Rear
Axle Speed Sensor”,
page 36 .
ling. Refer to
38 .
❑ Before inserting sensor,
clean inner surface of
mounting hole and coat
with Hot Bolt Paste - G
052 112 A3- . AG. Volkswagen AG d
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❑ Refer to ⇒ Suspension,
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Wheels, sSteering;
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Gr. 42 ;sWheel Bearing
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and Trailing Arm; Over‐

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⇒ “2.6.2 Brake Shield,

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6 - Bolt
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❑ 12 Nm
❑ Quantity: 3
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atio
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Wheel Bearing .
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9 - Dust Cap
Wheel Bearing .
10 - Brake Rotor
❑ Diameter 272 mm
❑ Brake rotor thickness 10 mm

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❑ Check the thickness.
horis Refer to ⇒ Maintenance ; Booklet 36.1
tee ; Procedure Descriptions; Front and Rear
Brake Rotors, auChecking Brake Pad Thickness and Condition o.r a
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12 - Brake Pads
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❑ Thickness without protective plate 11 mm
❑ Wear limit without protective plate 3 mm
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❑ Check the thickness. Refer to ⇒ Maintenance ; Booklet 36.1 ; Procedure Descriptions; Front and Rear
Brake Rotors, Checking Brake Pad Thickness and Condition .
s
❑ Always replace on both sides of the axle.
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❑ Removing and installing. Refer to ⇒ “2.2 Brake Pads, Removing and Installing”, page 60 .
inform
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13 - Brake Carrier
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❑ Overview. Refer to ⇒ “2.1 Overview - Rear Brake Caliper”, page 100 .

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16 - Brake Caliper
❑ Do not detach the brake line when replacing the brake pads.
❑ Parking brake must be adjusted after repair work or replacing.
❑ Adjusting the parking brake. Refer to ⇒ “3.2 Parking Brake, Adjusting”, page 81 .
17 - Parking Brake Cable
❑ Overview. Refer to ⇒ “3.1 Overview - Parking Brake”, page 81 .
❑ Adjusting. Refer to ⇒ “3.2 Parking Brake, Adjusting”, page 81 .
❑ Removing and installing. Refer to ⇒ “3.3 Rear Brake Cable, Removing and Installing”, page 82 .
18 - Bolt
❑ 35 Nm
❑ Quantity: 2
❑ Self-locking
19 - Brake Line
❑ 35 Nm
❑ Vehicles with banjo bolt
2. Rear Brakes 57
2.1.2 Overview - Rear Brakes, Torsion Beam Axle

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pt
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1 - Bolt
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❑ 8 Nm
2 - Wheel Speed Sensor
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Axle Speed Sensor”,
page 36 .
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3 - Bolt
❑ 90 Nm +90°
❑ Quantity: 2
4 - Brake Line
❑ 35 Nm
5 - Subframe
❑ Refer to ⇒ Suspension,
Wheels, Steering; Rep.
Gr. 42 ; Rear Axle;
Overview - Rear Axle
⇒ “3.1 Overview - Park‐
ing Brake”, page 81 .
❑ Adjusting. Refer to ⇒ “3.2 Parking Brake, Adjusting”, page 81 .
❑ Removing and installing. Refer to ⇒ “3.3 Rear Brake Cable, Removing and Installing”, page 82 .
7 - Cover Plate
8 - Axle Stub
Wheel Bearing .
9 - Bolt
❑ 30 Nm +90°

❑ Quantity: 4
Wheel Bearing .
11 - Bolt
Wheel Bearing .
12 - Brake Rotor
❑ Diameter 252 mm
❑ Brake rotor thickness 10 mm
❑ Wear limit: 8 mm
❑ Replace both sidesagen
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15 - Brake Carrier
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16 - Brake Pads
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❑ Wear limit without protective plate 3 mm
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❑ Always replace on both sides of the axle.

m
❑ Removing and installing. Refer to

com
tion in
⇒ “2.2.2 Brake Pads, Torsion Beam Axle, Removing and Installing”, page 63 .
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Prote AG.
18 - Bolt
❑ 35 Nm
❑ Quantity: 2
❑ Self-locking
2. Rear Brakes 59
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es, in part or in w
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2.2.1 Brake Pads, Multi-Link Rear Axle, Re‐
moving and Installing
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♦ Brake Caliper Tool - T10165-

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♦ Bolt - Wheel hub with wheel bearing

♦ Dust cap
♦ Bolts - Brake caliper to brake carrier
Installed Location on a Multi-Link Suspension.
1 - Brake caliper
B - Multi-link suspension.
Removing
Note
WARNING
Adjust the brake piston is permitted only with the Brake Caliper
Tool - T10165- .


– Remove the brake caliper -1- from the brake carrier.

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♦ The repair kit has 4 self-locking screws for installing the brake
caliper. Always use these.
location.
2. Rear Brakes 61
Press the Piston Back.
WARNING
out of the brake fluid reservoir using a bleeder bottle. Other‐
wise, especially if reservoir has been topped off, fluid will
overflow and cause damage.
– Install the Brake Caliper Tool - T10165- so that the collar on

the Resetting & Extracting Tool - Plate - T10165/1- is touching.
– Use the Resetting & Extracting Tool - Plate - T10165/1- to help
you bolt it on.
– Turn the thumbwheel on the Brake Caliper Tool - T10165- to
the right to install the piston. Be careful not to damage the
piston collar.
Note
For pistons that are difficult to move, an open-end wrench (size

13 mm) can be applied at the appropriate wrench surface
-arrow A-.
– check the protective caps for damage and correct seating

-item 9- ⇒ Item 9 (page 102) .
– Check the guide pins for ease of movement -item 8-
⇒ Item 8 (page 102) .
– install the brake pads -2- with the spring -1- in the opening in
the brake carrier -3-.
olkswagen AG
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– Use new self-locking bolts -arrows-.

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♦ Refer to ⇒ “2.1 Overview - Rear Brakes”, page 55
♦ Refer to ⇒ “2.1 Overview - Rear Brake
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Installed Location of the Brake Caliper on a Torsion Beam Axle
1 - Brake caliper
A - Torsion beam axle
Removing
Note
WARNING
Tool - T10165- .

2. Rear Brakes 63

– Remove the bolts -arrows-.
– While doing so counterhold the guide pin on the brake carrier
with a suitable wrench.
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pads on the brake carrier -1- and remove any corrosion.
Installing
Note
♦ The repair kit has four self-locking screws for installing the
brake caliper. Always use these.
location.

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– Turn the thumbwheel on the Brake Caliper Tool - T10165- to
mer
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⇒ Item 8 (page 102) .
– Install new brake pads -arrows- in the brake carrier.

– Carefully install the brake caliper on the brake carrier.
– Tighten the brake caliper -1- to the brake carrier.

– Use new self-locking bolts -arrows-.
– Tighten the brake caliper to the brake carrier.
wrench.
– After replacing brake pads, depress brake pedal firmly several
2. Rear Brakes 65
– Brake fluid level must be between the markings -1- and -2-.
Gr. 44 ; Wheels and Tires; Wheel Bolt Tightening Specifica‐
tions .
2.3 Brake Caliper, Removing and Installing

⇒ “2.3.1 Brake Carrier, Multi-Link Rear Axle, Removing and In‐
stalling”, page 66
⇒ “2.3.2 Brake Caliper, Torsion Beam Axle, Removing and In‐
2.3.1 Brake Carrier, Multi-Link Rear Axle, Re‐ agen

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2. Rear Brakes 67
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Caution


♦ Bolt - Subframe to brake carrier
♦ Bolt - Axle stub to subframe
♦ Dust cap
2. Rear Brakes 69
Removing
Note
♦ Work procedure applies only for replacing or when performing

uneven.

-arrow-.
– Disengage the parking brake cable -1- from the lever on the
brake caliper -2-.
– Squeeze the retainers -3-.
– Remove the parking brake cable -1- from the bracket -4- on
the brake caliper.
– Connect the bleed hose -1- from the bleeder bottle to the brake
caliper bleed valve and open the bleed valve.
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♦ Replace the self-locking screws for installing the brake caliper.
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♦ After installing, press the brake pedal several times firmly to

properly seat brake pads in their normal operating position.
• Piston is pressed back. Refer to ⇒ page 65 .

• Brake pads sit on the brake carrier.
⇒ Item 8 (page 102) .
2. Rear Brakes 71
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– Attach the brake hose connection -1- and the banjo bolt -2- to
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– Push the parking brake cable -1- through the bracket -4- on
the brake caliper until the tabs -3- engage.
-arrow-.
– Engage the parking brake cable -1- in the lever on the brake
caliper -2-.
– Adjust parking brake. Refer to
position.
♦ For installing the wheel bolts. Refer to ⇒ Suspension, Wheels,
Steering; Rep. Gr. 44 ; Wheels and Tires; Wheel Bolt Tight‐
ening Specifications .
2.4 Brake Carrier, Removing and Installing

♦ Multipoint Socket - T10035-

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hose.
2. Rear Brakes 73
– Unscrew the threaded connection -arrows- on the brake car‐

rier -1-.
– Remove the brake carrier -1-.
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2.5 Brake Rotor, Removing and Installing

Removing
Note
uneven.


⇒ “2.2.1 Brake Pads, Multi-Link Rear Axle, Removing and In‐
hose.
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2. Rear Brakes 75
– Loosen the threaded connection -arrow- on the brake rotor

-1-.
– Remove the brake rotor.
Cleaning
WARNING
Note
Installing
Note
♦ Carefully clean before installing.

♦ Check for wear, damage, dimension and damaged threading.
♦ Always replace pads on both sides of axle if worn.
– Thoroughly clean the contact surfaces on athe

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2.6 Brake Shield, Removing and Installing

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Removing
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Arm; Overview - Wheel Bearing .
rrectness of i
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2. Rear Brakes 77
– Unscrew the threaded connection -arrows- on the cover plate

-1-.
– Remove the cover plate -1- and the stub axle.
Cleaning
WARNING
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Installing
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eral times to seat the brake pads ecorrectly in their operating
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t to the co
Rep. Gr. 42 ; Wheel Bearing and Trailing Arm; Overview -

Wheel Bearing .
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2.6.2 Brake Shield, Multi-Link Rear Axle, Re‐

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Removing
Note
uneven.

– Remove the wheel bearing unit. Refer to ⇒ Suspension,
Wheels, Steering; Rep. Gr. 42 ; Wheel Bearing and Trailing
Arm; Overview - Wheel Bearing .
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2. Rear Brakes 79
– Unscrew the threaded connection -arrows- on the cover plate

-1-.
– Remove cover plate -1-.
Cleaning
WARNING
Note
Installing
location.
AG. Volkswagen AG d
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– Before moving the vehicle, pressVol
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not
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position. ris tee
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♦ Wheel bearing unit. Refer to ⇒ Suspension, Wheels, Steering;

Rep. Gr. 42 ; Wheel Bearing and Trailing Arm; Overview -
rrectness of i
Wheel Bearing .
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⇒ “3.2 Parking Brake, Adjusting”, page 81
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⇒ “3.2 Parking Brake,
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8 - Guide Tube
❑ Make sure the mount fits
correctly.
9 - Mount
ling. Refer to
⇒ “3.3.1 Rear Brake Ca‐
ble, Multi-Link Rear
Axle, Removing and In‐
11 - Parking Brake Indicator
Lamp Switch - F9-
3.2 Parking Brake, Adjusting
Note
A new adjustment is necessary only after replacing brake cables,

brake calipers or brake rotors.
Adjusting
3. Parking Brake 81
– Press the brake pedal forcefully at least three times.

– Apply the parking brake three times and then release.
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Gr. 68 ; Center Console; Overview - Center Console .

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3.3 Rear Brake Cable, Removing and In‐

stalling
⇒ “3.3.1 Rear Brake Cable, Multi-Link Rear Axle, Removing and
Installing”, page 82
⇒ “3.3.2 Rear Brake Cable, Torsion Beam Axle, Removing and
Installing”, page 85
3.3.1 Rear Brake Cable, Multi-Link Rear Axle,

Removing
– Loosen the parking brake lever.
• Parking brake lever in released position.

– Press the lever -2- located on the brake caliper in the direction
of the -arrow- and disengage the brake cable -1-.
– Squeeze the tabs -3- and remove the brake cable from the
bracket -4- on the brake caliper.
– Remove the center console. Refer to ⇒ Body Interior; Rep.
– Loosen the adjusting nut -1- until it is possible to disengage

the parking brake cable -2- from the compensator bracket
-3-.
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3. Parking Brake 83
Installing
– Pay attention that the guide tube and the seal are seated cor‐
rectly.
– Push the brake cable -1- in the guide tube -2- until stop.
– Engage the brake cable -1- in the bracket -3- and push in wire.
– Engage the brake cable at the marking -arrow-.
– Insert the brake cable -1- into the guide -arrow B- on the
bracket -2- opposite the direction of -arrow-.
– Clip the brake cable -1- back into the retainer -arrow A- on the
bracket -2-.
AG. Volkswagen AG d
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-arrow- and engage the brake cable -1-.
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– Install the parking brake cable -2- in the compensator bracket

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-3-.
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– Pay attention that the guide tube is seated correctly in the

mount -item 9- ⇒ Item 9 (page 81) .
nf
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– Pretension the parking brake cable using the adjustment nut

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– Adjust the parking brake. Refer to

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♦ Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center Console; Over‐
Co
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view - Center Console . t. C rig
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3.3.2 Rear Brake Cable, Torsion Beam Axle,

Removing olkswage es n
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– Loosen the wheel bolts. ir se
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– Raise the vehicle. ss
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– Loosen the parking brake lever.
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• Parking brake lever in released position.
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– Press the lever -2- located on the brake caliper in the direction hole
of the -arrow- and disengage the brake cable -1-.
spec
es, in part or in w
– Squeeze the tabs -3- and remove the brake cable from the
t to the co
bracket -4- on the brake caliper.
– Remove the center console. Refer to ⇒ Body Interior; Rep.
rrectness of i
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– Loosen the adjusting nut -1- until it is possible to disengage
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– Disengage the brake cable -1- from the bracket -3- and pull it
from the guide tube -2-.
– Release the bracket from the rear axle and remove upward.
– Remove the brake cable rearward from the guide bushing on
the rear axle.
3. Parking Brake 85
Installing
– Guide the brake cable from the rear in the guide bushing.
– Clip in the bracket on the rear axle.
– Check for secure fit by pulling on it.
– Pay attention that the guide tube and the seal are seated cor‐
rectly.
– Push the brake cable -1- in the guide tube -2- until stop.
– Engage the brake cable -1- in the bracket -3- and push in wire.
– Engage the brake cable at the marking -arrow-.
– Push the brake cable -1- through the bracket -4- on the brake
caliper until both tabs -3- engage.
– Press the lever -2- located on the brake caliper in the direction
of the -arrow- and engage the brake cable -1-.
The brake cable must be installed without tension between the
bracket on the brake caliper and the bracket on the rear axle.
– Install the parking brake cable -2- in the compensator bracket

-3-.
– Pay attention that the guide tube is seated correctly in the
mount -item 9- ⇒ Item 9 (page 81) .
G. Volkswagen AG d
– Pretension the parking brake cable using the adjustment nut lkswagen A oes
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– Adjust the parking brake. Refer to tho eo
⇒ “3.2 Parking Brake, Adjusting”, page 81 . au ra
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♦ Refer to ⇒ Body Interior; Rep. Gr. 68 ; Center Console; Over‐

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view - Center Console .

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4 Brake Pedal
⇒ “4.1 Overview - Brake Pedal”, page 87
⇒ “4.2 Brake Pedal, Removing from Brake Booster”, page 88
⇒ “4.3 Brake Pedal, Attaching to Brake Booster”, page 89
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⇒ “4.4 Brake Pedal, Removing and Installing”, page 89kswagen AG does
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⇒ “4.5 Mounting Bracket, Removing and Installing”,
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Do not lubricate or grease the mounting pin. The mounting pin must remain dry.
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1 - Self-Locking Hex Nut
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❑ 25 Nm
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❑ Bolt tightening se‐

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2 - Mounting Pin
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❑ Remove the bracket to p by
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agen
❑ Removing: Turn the

mounting pin clockwise,
while doing so the tabs
on the mounting pin
break
❑ Replacing the mounting
pin
❑ Do not lubricate or
grease the mounting
pin. The mounting pin
must remain dry
❑ Installing: Turn the
mounting pin counter-
clockwise, until the tabs
at stop engage audibly
3 - Foot Pedal Assembly/
Bracket
ling. Refer to
⇒ “4.5 Mounting Brack‐
et, Removing and Instal‐
ling”, page 90 .
4 - Bearing Bushing
❑ Not exchangeable,
4. Brake Pedal 87
make sure that it is in‐

stalled in the correct position.
5 - Brake Pedal
❑ Separate the brake pedal from brake booster. Refer to
⇒ “4.2 Brake Pedal, Removing from Brake Booster”, page 88 .
❑ Brake pedal to brake booster connecting. Refer to
⇒ “4.3 Brake Pedal, Attaching to Brake Booster”, page 89 .
❑ Removing and installing. Refer to ⇒ “4.4 Brake Pedal, Removing and Installing”, page 89 .
6 - Cover
7 - Bearing Bushing
❑ Not exchangeable, make sure that it is installed in the correct position.
8 - Bearing Shell
9 - Mount
❑ For the ball head on the brake booster push rod
10 - Clip n AG. Volkswagen AG do
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❑ Install in both holes on the bracket. utho tee
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Tightening Sequence
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4.2 Brake Pedal, Removing from Brake

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Booster
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Special tools and workshop equipment required thi

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♦ Brake Servo Release Tool - T10159A-

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– Remove the footwell cover on the driver side. Refer to ⇒ Body
yi Co
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Interior; Rep. Gr. 68 ; Storage Compartments and Covers .
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– First press brake pedal
s auin direction of brake booster and hold. ra
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2 - Pressure rod
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3 - Retaining tabs
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– Insert Release Tool - Brake Servo - T10159- and pull in direc‐
ot
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tion of driver seat. When doing this, counter-hold on brake
, is n
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pedal. (At this moment the pedal must not be allowed to move
hole
to the driver seat). The mount retaining tabs -3- will thereby be
spec
es, in part or in w
pressed off the ball head of the pushrod -2-.
t to the co
The process of separating the brake pedal from the brake booster
is shown with the pedal assembly removed.
rrectness of i
– Pull Release Tool - Brake Servo - T10159- and brake pedal
together toward the driver seat. (This will pull the brake pedal
l purpos
off the push rod ball head).

nform
mercia
♦ Footwell cover on the driver side. Refer to ⇒ Body Interior;
a
com
ti
Rep. Gr. 68 ; Storage Compartments and Covers; Component
on in
Location Overview - Storage Compartment/Covers .
r
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4.3 Brake Pedal, Attaching to Brake Booster
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brake pedal toward the brake booster until the ball head en‐
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– Check the lock by pulling on the brake pedal.
AG.
4.4 Brake Pedal, Removing and Installing

Removing the brake pedal separately from the vehicle is not pos‐
sible.
– Remove the bracket. Refer to
page 90 .
Note
Remove the brake pedal from the removed bracket.
4. Brake Pedal 89
olkswagen AG
ag en AG. V
Golf 2015 ➤ , Golf Variant 2015 o➤
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– Turn the mounting pins clockwise
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-1- = Hex Socket Wrench SW 14.
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At the same time the tabs -B- break. Replacing the mounting pin.
es, in part or in w
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– Remove the clip from the mounting pin.
– Remove the mounting pin from the right.
rrectness of i
– Remove the brake pedal from the bracket.
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Installing
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Install in reverse order of removal. Pay attention to the following:

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Replace the mounting pin and clip.
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Do not lubricate or grease the mounting pin. The mounting pin
must remain dry.
– Install the brake pedal in the bracket.

– Push the mounting pin from the right to the left through the
bracket and brake pedal.
– Place the clip on the mounting pin.
– Turn the mounting pins counter clockwise direction of the
-arrow- until the latches -A- engage audibly in the bracket.
– Install the pedal assembly and the bracket. Refer to
page 90 .
4.5 Mounting Bracket, Removing and Instal‐

ling
– Remove the side cover from the driver side instrument panel.
Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instrument Panel;
Instrument Panel Side Cover, Removing and Installing .
– Remove the driver side center console cover. Refer to ⇒ Body
Interior; Rep. Gr. 68 ; Rearview Mirror; Rearview Mirror, Re‐
moving and Installing .
– Remove the driver side storage compartment. Refer to ⇒
Body Interior; Rep. Gr. 68 ; Storage Compartments and Cov‐
ers .
– Remove the driver side instrument panel cover. Refer to ⇒

ers; Driver Side Instrument Panel Cover, Removing and In‐

stalling .
– Remove the knee airbag. Refer to ⇒ Body Interior; Rep. Gr.
69 ; Knee Airbags; Overview - Knee Airbag .
– Remove the footwell vent on the driver side. Refer to ⇒ Heat‐
ing, Ventilation and Air Conditioning; Rep. Gr. 87 ; Air Routing;
Overview - Air Routing and Air Distribution in Passenger Com‐
partment .
– Remove the brake pedal crash bolster and set aside. Refer to
⇒ Body Interior; Rep. Gr. 70 ; Instrument Panel Central Tube;
Overview - Instrument Panel Central Tube .
– Remove the Data Bus On Board Diagnostic Interface - J533-
and set aside. Refer to ⇒ Electrical Equipment; Rep. Gr. 97 ;
Control Modules; Overview - Data Bus On Board Diagnostic
Interface .
– Disconnect brake pedal from brake booster. Refer to
⇒ “4.2 Brake Pedal, Removing from Brake Booster”,
page 88 .
– Remove the accelerator pedal position sensor connector.
– Remove the bolt -1- and fold the footwell trim panel -2- in the
direction of the -arrow- into the vehicle interior.
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– Remove the nuts -1 to 4-.

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– Carefully remove the pedal assembly.

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Installing
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– Connect the brake pedal together with the brake booster. Re‐
fer to
rrectness of i
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4. Brake Pedal 91
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Tightening Sequence au
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♦ Refer to ⇒ “4.1 Overview - Brake Pedal”, page 87
y li
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♦ Crash bolster. Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instru‐
ot
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ment Panel Central Tube; Overview - Instrument Panel Cen‐ , is n
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tral Tube .
hole
spec
♦ Footwell vent. Refer to ⇒ Heating, Ventilation and Air Condi‐
es, in part or in w
t to the co
tioning; Rep. Gr. 87 ; Air Routing; Overview - Air Routing and
Air Distribution in Passenger Compartment .
♦ Knee airbag. Refer to ⇒ Body Interior; Rep. Gr. 69 ; Knee
rrectness of i
Airbags; Overview - Knee Airbag
l purpos
♦ Covers on the driver side. Refer to ⇒ Body Interior; Rep. Gr.

68 ; Storage Compartments and Covers; Component Location
Overview - Storage Compartment/Covers .
nform
mercia
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tion in
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5 Special Tools
Special tools and workshop

equipment required
5-50Nm - VAG1331-
40-200Nm - VAG1332-
♦ Piston Resetting Tool -
T10145-
AG. Volkswagen AG d
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5. Special Tools 93
AG. Volkswagen AG d
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♦ Torque Wrench 1331 rise
d
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5-50Nm - VAG1331- utho eo
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40-200Nm - VAG1332-
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♦ Brake Caliper Tool -
erm
ab
T10165-
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♦ Multipoint Socket - T10035-

♦ Brake Servo Release Tool - T10159A-
AG. Volkswagen AG d
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5. Special Tools 95
♦ Trim Removal Wedge - 3409-
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47 – Hydraulic Components
1 Front Brake Caliper
⇒ “1.1 Overview - Front Brake Caliper”, page 97
⇒ “1.2 Brake Caliper Piston, Removing and Installing”,
page 98
1.1 Overview - Front Brake Caliper
1 - Dust Cap
❑ Install onto bleeder
valve
2 - Bleeder Valve
AG. Volkswagen AG d
❑ 10 Nm agen oes
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❑ Apply a thin risedcoat of As‐ ara
nte
semblyutPaste - G 052
ho eo
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150 A2-
ss a to the threads c
before screwing in.
ce
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un
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an
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3 - Hex Bolt
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❑ 35 Nm
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❑ Replace after removing wit

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4 - Guide Pin
hole
spec
es, in part or in w
5 - Cap
t to the co
❑ Lubricate the groove

with the grease that
comes with the repair kit
rrectness of i
and then install the cap

l purpos
into the groove on the

brake carrier and the
guide pin.
nform
ercia
6 - Brake Carrier
m
a
com
ti
❑ Is assembled with the

on in
guide pins and cap as

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well as with sufficient

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grease on the guide

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pins.
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❑ If protective caps or
Co
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use repair kit. Use sup‐ p by
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plied grease packet to
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lubricate guide pins.
AG.
7 - Cap
ling. Refer to ⇒ “1.2 Brake Caliper Piston, Removing and Installing”, page 98 .
❑ Do not damage when installing piston
8 - Piston
❑ Removing and installing. Refer to ⇒ “1.2 Brake Caliper Piston, Removing and Installing”, page 98 .
❑ Apply thin coat of Assembly Paste - G 052 150 A2- to piston before inserting
9 - Seal
10 - Brake Caliper
1. Front Brake Caliper 97

1.2 Brake Caliper Piston, Removing and In‐

stalling
Removing
– Force piston from brake caliper using compressed air.
Place a wooden board into the recess of the caliper housing so it
is not damaged.
AG. Volkswagen AG d
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– Remove seal with Trim Removal Wedge - 3409- .
ility
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When removing, make sure that surface of cylinder is not dam‐
h re
ole,
aged.
spec
t to the co
rrectness o
cial p
f inform
mer
atio
m
Installing
o
n
c
i
or
n
– Clean the surfaces on the pistons and seal with mineral spirits. thi
te
sd
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– Apply a thin coat of installation paste G 052 150 A2 on the

pr
cum
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piston and the seal before installing.

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– Insert oil seal into brake caliper. C py
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– Place the cap with the outer sealing lip on the piston. op Vo
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98 Rep. Gr.47 - Hydraulic Components

Golf
n AG.2015
Volksw➤ , nGolf
age AG doVariant 2015 ➤
wage es n
y Volks Brake System - Edition
ot g 12.2015
d b ua
ran
ir se tee
– Insert inner sealing lip in cylinder groove with Trim
uth Removal
o
or
Wedge - 3409- . ss
a ac
ce
le
un
Hold piston in front of brake caliper for this procedure.
pt
an
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erm
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ility
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spec
t to the co
rrectne
– Press piston into the brake caliper using piston resetting tool.
ss
The outer seal lip of the cap thereby slips into the groove on the
o
cial p
f i
piston.
nform
mer
atio
om
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c
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or
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1. Front Brake Caliper 99

2 Rear Brake Caliper

⇒ “2.1 Overview - Rear Brake Caliper”, page 100
⇒ “2.2 Brake Caliper Piston, Removing and Installing”,
page 103
2.1 Overview s-wRear

agen
AG.Brake
VolkswageCaliper
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⇒ “2.1.1 Overview e-dRear
by Brake Caliper, Multi-Link RearuaAxle”,
ran
page 100 thoris tee
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⇒ “2.1.2 Overview
ss - Rear Brake Caliper, Torsion Beam Axle”, c
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page 102
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2.1.1 Overview - Rear Brake Caliper, Multi-Link Rear Axle
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Note
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♦ Install complete repair kit when servicing.
t to the co
♦ Only use mineral spirits to clean brake parts.
♦ Apply thin coat of Lithium Grease - G 052 150 A2- to brake cylinders, pistons and seals.
rrectness of i
♦ When servicing or replacing the brake caliper the brake caliper must be pre-bleed before installing in the
l purpos
vehicle (without brake pads). Refer to ⇒ “2.2.2 Brake Caliper, Pre-Bleeding”, page 105 .
nform
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1 - Brake Caliper
❑ Vehicles with parking
brake cable lever
❑ If a leak exists at lever
for parking brake cable,
replace brake caliper.
❑ Pre-bleed brake caliper
after replacing. Refer to
Brake Caliper”,
page 100 .
2 - Bleeder Valve
❑ 10 Nm
❑ Before installing lightly
coat the threads with
Lithium Grease - G 052
150 A2- .
3 - Dust Cap
4 - Bolt
❑ 35 Nm
❑ Quantity: 2
❑ Self-locking
❑ When loosening and
tightening, counterhold
at guide pin
5 - Guide Pin
❑ Vehicles with recess
❑ Lubricate before instal‐
ling the cap
the Parts Catalog n AG. Volkswagen AG do
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6 - Guide Grommet d b ua
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7 - Cap aut or
ac
ss
❑ Install on brake carrier and guide pin.
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8 - Guide Pin
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❑ Lubricate before installing the cap

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ility
ot
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9 - Brake Carrier
, is n
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❑ Supplied as an assembled replacement part with sufficient grease on guide pins.

hole
spec
❑ If protective caps or guide pins are damaged use repair kit. Use supplied grease packet to lubricate guide
es, in part or in w
t to the co
pins.
rrectness of i
10 - Cap
❑ Pull onto piston with outer sealing lip
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nform
ercia
11 - Piston with Automatic Adjustment

m
a
com
tio
❑ Apply thin coat of Assembly Paste - G 052 150 A2- to piston before inserting
n in
r
te o
thi
12 - Seal
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2. Rear Brake Caliper
2.1.2 Overview - Rear Brake Caliper, Torsion Beam Axle
1 - Cap
❑ Pull onto piston with out‐
er sealing lip
ling. Refer to
⇒ “2.2.1 Brake Caliper
Piston, Removing and
Installing”, page 103 .
2 - Piston with Automatic Ad‐
justment
ling. Refer to
⇒ “2.2.1 Brake Caliper AG. Volkswagen AG d
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Piston, Removing and byV
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Installing”, page 103 . rised
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❑ Apply thin coat of As‐ aut ra
c
sembly Paste - G 052 ss
ce
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150 A2- to piston before

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inserting
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3 - Seal
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ling. Refer to
hole
⇒ “2.2.1 Brake Caliper
spec
Piston, Removing and
es, in part or in w
t to the co
Installing”, page 103 .
4 - Brake Caliper
rrectness of i
ling. Refer to
l purpos
⇒ “2.3 Brake Caliper,

Removing and Instal‐
ling”, page 66 .
nform
ercia
❑ Vehicles with parking

m
at
brake cable lever
om
ion
c
in t
❑ Replace brake caliper if
or
his
e
leaking at parking brake

at
do
riv
cable lever
p
cum
for
❑ Pre-bleed brake caliper after repairing. Refer to

en
ng
t.
yi
⇒ “2.3.1 Brake Carrier, Multi-Link Rear Axle, Removing and Installing”, page 66 .
Co
Cop py
ht. rig
5 - Bleeder Valve
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❑ 10 Nm Prote
cted AG.
agen
❑ Apply a thin coat of Assembly Paste - G 052 150 A2- to the threads before screwing in
6 - Dust Cap
7 - Bolt
❑ 35 Nm
❑ Self-locking
❑ When loosening and tightening, counterhold at guide pin
8 - Guide Pin
❑ Lubricate before installing the cap
❑ Check for ease of movement
9 - Cap
❑ Install on brake carrier and guide pin

❑ Check for damage and correct seating
10 - Brake Carrier
❑ Supplied as an assembled replacement part with sufficient grease on guide pins
❑ If protective caps or guide pins are damaged use repair kit. Use supplied grease packet to lubricate guide
pins
2.2 Brake Caliper Piston, Removing and In‐

stalling
⇒ “2.2.1 Brake Caliper Piston, Removing and Installing”,
page 103
⇒ “2.2.2 Brake Caliper, Pre-Bleeding”, page 105
2.2.1 Brake Caliper Piston, Removing and In‐

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AG. Volkswagen AG d
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Special tools and workshop equipment required edb ran
ris tee
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♦ Brake Caliper Tool - T10165- au
or
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itte
Removing
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WARNING
wit
, is n
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hole
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es, in part or in w
Tool - T10165- .
t to the co
– Install the Brake Caliper Tool - T10165- so that the collar
rrectness of i
touches the piston.
l purpos
– Remove piston from brake caliper by turning knurled wheel

toward left.
nform
ercia
– For pistons that are difficult to move, an open-end wrench (size

m
at
om
io
-arrow A-.
n
c
in t
or
his
ate
do
priv
cum
for
en
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– Remove the sealing ring using the Trim Removal Wedge -
op Vo
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2. Rear Brake Caliper 103

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Installing byV
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Install in reverse order
th of removal. Note the following:
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pt
Note
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♦ Install complete repair kit when servicing.
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♦ Only use mineral spirits to clean brake parts.
, is n
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hole
♦ New brake calipers are filled with brake fluid and are pre-bled.
spec
es, in part or in w
♦ Apply thin coat of Assembly Paste - G 052 150 A2- to brake
t to the co
cylinders, pistons and seals.
♦ In case of repair, brake calipers must always be pre-bled be‐
rrectness of i
fore being installed into vehicle (without brake pads). Refer to
⇒ “2.2.2 Brake Caliper, Pre-Bleeding”, page 105 .
l purpos
– Clean the surfaces on the pistons and seal only with mineral
nform
ercia
spirits and then dry.

m
at
om
– Place the sealing ring in the groove.
ion
c
in t
or
– Apply a thin coat of Assembly Paste - G 052 150 A2- on the
his
te
piston and the seal before installing.

a
do
priv
cum
or
– Place the cap with the outer sealing lip on the piston.
f
en
ng
t.
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Cop py
– Insert inner sealing lip in cylinder groove with Trim Removal
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Wedge - 3409- . p by
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cted agen
– Hold piston in front of brake caliper for this procedure. Prote AG.
– Install the pistons by turning clockwise.

– Be careful not to damage the cap.
you bolt it on.
– Install by turning the thumbwheel on the Brake Caliper Tool -
T10165- clockwise.
The automatic adjustment in brake caliper is destroyed when pis‐
ton is moved with piston resetting tool (for example T 10145) or
foot brake is pressed.

2.2.2 Brake Caliper, Pre-Bleeding

– Open the bleeder valve -arrow A- and using a standard bleed‐
er bottle, fill with brake fluid until brake fluid with no bubbles
flows from the threaded hole (brake hose connection)
-arrow B-. Close the bleed valve.
Position brake caliper as shown during pre-bleed procedure.
AG. Volkswagen AG d
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es, in part or in w
t to the co
rrectness of i
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nform
mercia
at
om
ion
c
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or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
ht. rig
rig ht
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2. Rear Brake Caliper 105

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3 Brake Booster/Brake Master Cylin‐
thoris tee
or
au
ss der ac
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⇒ “3.1 Overview - Brake Booster/Brake Master Cylinder”,
an
itte
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page 106
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⇒ “3.2 Brake Lamp Switch, Removing and Installing”, page 108
wit
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⇒ “3.3 Brake Master Cylinder, Removing and Installing”,
hole
page 110
spec
es, in part or in w
⇒ “3.4 Brake Booster, Removing and Installing”, page 113
t to the co
⇒ “3.5 Brake Fluid Reservoir, Removing and Installing”,
page 118
rrectness of i
3.1 Overview - Brake Booster/Brake Master Cylinder
l purpos
nform
ercia
WARNING
m
at
om
Only use new brake fluid conforming to VW standard (VW 501
ion
14).
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
1 - Hex Nut
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Cop py
❑ 25 Nm ht. rig
rig ht
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❑ Self-locking
co Vo
by lksw
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AG.
❑ Tightening sequence.
Refer to
⇒ Fig. ““Tightening Se‐
quence”“ , page 108
2 - Bracket/Pedal Assembly
❑ Assembly sequence.
Refer to
⇒ “4.1 Overview - Brake
Pedal”, page 87 .
❑ Mounting bracket, re‐
moving and installing.
Refer to
⇒ “4.5 Mounting Brack‐
et, Removing and Instal‐
ling”, page 90 .
❑ Separate the brake ped‐
al from brake booster.
Refer to
⇒ “4.2 Brake Pedal, Re‐
moving from Brake
Booster”, page 88 .
❑ Brake pedal to brake
booster, connecting.
Refer to
⇒ “4.3 Brake Pedal, At‐
taching to Brake Boos‐
ter”, page 89 .
❑ Brake Pedal, removing
and installing. Refer to
⇒ “4.4 Brake Pedal, Re‐
moving and Installing”,
page 89 .

3 - Bulkhead
4 - Hex Nut
❑ 23 Nm
❑ Self-locking
5 - Brake Master Cylinder
❑ Cannot be serviced. Replace as complete unit if malfunctioning.
❑ Removing and installing. Refer to ⇒ “3.3 Brake Master Cylinder, Removing and Installing”, page 110 .
6 - Brake Lamp Switch - F-
❑ Removing and installing. Refer to ⇒ “3.2 Brake Lamp Switch, Removing and Installing”, page 108 .
7 - Bolt
❑ 8 Nm
8 - Brake Line
❑ 14 Nm
❑ Brake master cylinder/secondary piston circuit to the ABS Hydraulic Unit - N55-
9 - Brake Line
❑ 14 Nm
❑ Brake master cylinder/primary piston circuit to the ABS Hydraulic Unit - N55-
10 - Sealing Plug
❑ Moisten with brake fluid and press into brake fluid reservoir
11 - Brake Fluid Level Warning Switch - F34-
12 - Brake Fluid Reservoir
❑ Bolt 8 Nm
13 - Vacuum Hose AG. Volkswagen AG d
agen oes
❑ Vehicles with check valve Volksw not
gu
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❑ Insert into brake booster rise
d
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❑ On some vehicles with a gasoline engine
s a the Brake Booster Vacuum Sensor - G608- is installed.
ut ra
c Refer
to ⇒ “4.3 Vacuum Sensor G608 , Removing
s and Installing”, page 122 .
ce
e
nl
pt
du
14 - Cap an
itte
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15 - Seal ility
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❑ Master brake cylinder/brake booster

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16 - Seal
hole
spec
❑ Vacuum hose/brake booster

es, in part or in w
t to the co
17 - Brake Booster
❑ Functional check:
rrectness of i
– Vehicles with engine switched off, depress brake pedal firmly several times (to exhaust the vacuum in
l purpos
the unit).
– Depress and hold brake pedal with average foot pressure and start engine. If brake booster is working
nf
ercia
properly, pedal will be felt to give noticeably under foot (booster assistance becomes effective).
orm
m
atio
❑ Replace completely if there are malfunctions (check the vacuum system for the brake booster first; refer
om
n in
to ⇒ “4.4 Vacuum System, Checking”, page 123 )

or c
thi
e
❑ Removing and installing. Refer to ⇒ “3.4 Brake Booster, Removing and Installing”, page 113 .
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18 - Seal
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❑ Replacing
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❑ Attached, only at the factory
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❑ Do not replace the gluing on the brake booster and plenum chamber cop Vo
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Prote AG.
3. Brake Booster/Brake Master Cylinder 107

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Golf 2015 ➤ , Golf Variant 2015 ➤ olks
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Brake System - Edition 12.2015 ised b ara
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Tightening Sequence ss
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ility
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es, in part or in w
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rrectness of i
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3.2 Brake Lamp Switch, Removing and In‐

stalling
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Removing
om
n in
c
Diesel Vehicles
or
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te
sd
a
– Unclip the vacuum line from the air guide hose.

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– Open the clamps -1 and 2-.
en
ng
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op
– Remove the air guide hose.
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pyri by
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Vehicles with 2.0 L Gasoline Engine

– Remove the air guide hose -1-.


– Release the connector -1- from the Brake Lamp Switch - F-
and remove.
– Remove the Brake Lamp Switch - F- -2- bolt.
– Remove the Brake Lamp Switch - F- down from the brake
master cylinder and remove it upward from the retaining tab.
Installing
– Install in reverse order of removal.
♦ Refer to
⇒ “3.1 Overview - Brake Booster/Brake Master Cylinder”, page
106
♦ Refer to ⇒ Engine Mechanical, Fuel Injection and Glow Plug;
Rep. Gr. 23 ; Air Filter; Overview - Air Filter Housing .
AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
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aut ra
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un
pt
an
d
itte
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rm
ab
pe
ility
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wit
, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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rp
cum
fo
en
ng
t.
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Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

3.3 Brake Master Cylinder, Removing and

Installing
Special tools and work‐
shop equipment re‐
quired
5-50Nm - VAG1331-
- VAG1410-
♦ Brake Charger/
Bleeder Unit -
VAS5234-
Insert - Ring Wrench
- 11mm & 17mm -
VAG1331/2-
♦ Engine Bung Set - AG. Volkswagen AG d
VAS6122- agen oes
olksw not
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b ara
♦ Sealing Tool - rise
d
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T10249- utho eo
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s a c
s
♦ Sealing Plugs from
ce
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nl
the Repair Kit - 1H0
pt
du
an
698 311 A-
itte
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ility
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es, in part or in w
t to the co
rrectness of i
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ercia
orm
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or c
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Component Location
en
ng
t.
yi Co
op
1 - ABS Hydraulic Unit -
C py
t. rig
gh
N55- and ABS Control
ht
pyri by
Vo
o
Module - J104-
c by lksw
cted agen
Prote AG.
2 - Brake Booster
Removing
– If the vehicle has a
coded radio, get the
radio code from the
customer before be‐
ginning.

– Disconnect the bat‐

tery. Refer to ⇒ Elec‐
trical Equipment;
Rep. Gr. 27 ; Battery;
Battery, Disconnect‐
ing and Connecting .
– Remove the battery.
Refer to ⇒ Electrical
Equipment; Rep. Gr.
27 ; Battery; Battery,
Removing and Instal‐
ling .
– Remove the engine
cover. Refer to ⇒ En‐
gine Mechanical,
Fuel Injection and Ig‐
nition; Rep. Gr. 10 ;
Engine Cover; En‐
gine Cover, Remov‐
ing and Installing .
Diesel Vehicles
– Remove the air filter housing. Refer to ⇒ Engine Mechanical, olks
wage es n
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Fuel Injection and Glow Plug; Rep. Gr. 23 ; Air Filter; Aird bFilter
y V ua
ran
Housing, Removing and Installing . or
ise tee
th or
au ac
ss
ce
e
nl
pt
du
an
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
– Remove the air filter housing. Refer to ⇒ Engine Mechanical,
Fuel Injection and Ignition; Rep. Gr. 24 ; Air Filter; Air Filter
Housing, Removing and Installing .
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
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.


– Remove the battery holder. Refer to ⇒ Electrical Equipment;
Rep. Gr. 27 ; Battery; Battery Tray, Removing and Installing .
– Place sufficient lint-free cloths in the area of the engine and
transmission.
– Extract as much brake fluid as possible from the brake fluid
reservoir with the Brake Charger/Bleeder Unit - VAS5234- .
AG. Volkswagen AG d
agen oes
Vehicles with a Manual Transmission olksw not
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– Remove the supply hose -2- for the clutch rise master cylinder nte
tho eo
-3- from the brake fluid reservoir -4-.s au ra
c
s
– Seal the supply hose -2- for the clutch master cylinder -3- using
ce
le
un
pt
Sealing Tool - T10249- -1- or Engine Bung Set - VAS6122- .
an
d
itte
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erm
ab
– Tie up the return hose -2-.
ility
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is n
h re
ole,
spec
t to the co
– If equipped release the connector -2- from the Vacuum Sensor rrectne
- G608- .
ss o
cial p
– Release and remove the connector -3- from the Brake Fluid
inform
Level Warning Switch - F34- .

mer
atio

om
and remove.
c
i
or
n thi
te
sd
iva
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pr
cum
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fo
en
ng
t.
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Cop py
t. rig
gh ht
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– Remove the bolt -1- and pull the brake fluid reservoir -2- from
p by
co Vo
by lksw
the sealing plugs. Prote
cted AG.
agen

– Remove the brake lines -1- on brake master cylinder.

– Close the brake line with Sealing Plugs from the Repair Kit -
1H0 698 311 A- .
– Close the open connections on the brake master cylinder with AG. Volkswagen AG d
a suitable plug from the Engine Bung Set - VAS6122- . lksw
agen oes
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– Remove the nuts -2- from the brake master cylinder.rised b ran
tee
tho or
– Remove the heat shield, if equipped. s au ac
s
ce
le
– Carefully take brake master cylinder out of brake booster.
un
pt
an
d
itte
– Remove the Brake Light Switch - F- from brake master cylin‐
y li
erm
ab
der.
ility
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Installing
is n
h re
ole,
spec
– When installing together the brake master cylinder and brake
t to the co
booster, make sure that the push rod is correctly located in the
brake master cylinder.
rrectne
– Make sure the seal fits correctly when attaching the master
brake cylinder to the brake booster -item 15-
s
⇒ Item 15 (page 107) .
s o
cial p
f
– Make sure the sealing plugs are seated correctly in the brake
inform
master cylinder -item 10- ⇒ Item 10 (page 107) .
mer
atio
m
– Coat the plugs with brake fluid before pushing the brake fluid
o
n
c
reservoir into the master brake cylinder -item 10-
i
or
n thi
e
⇒ Item 10 (page 107) .

t
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pr
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um
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⇒ “6.2 Hydraulic System, Standard Bleeding”, page 132 .
en
ng
t.
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Cop py
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Vehicles with Manual Transmission
gh ht
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– The seals -2- must be located in the return hose -1- to the cted agen
Prote AG.
clutch master cylinder.
– Bleed the clutch mechanism. Refer to ⇒ Manual Transmis‐
sion; Rep. Gr. 30 ; Clutch Mechanism; Clutch Mechanism,
Bleeding .
♦ Refer to
106
Installing .
♦ Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Over‐
view - Battery .
3.4 Brake Booster, Removing and Installing

♦ Sealing Tool - T10249-

AG. Volkswagen AG d
agen oes
Golf 2015 ➤ , Golf Variant 2015 ➤ Volksw not
gu
y
Brake System - Edition 12.2015 rise
d b ara
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♦ Torque Wrench 1331 Insert - Ring Wrench - 11mm &ss17mm - c
VAG1331/2-
ce
e
nl
pt
du
an
itte
y li
erm
ab
♦ Hot air gun for example Wiring Harness Repair Set - Hot Air
ility
ot p
Blower - VAS1978/14A- .
wit
, is n
h re
hole
♦ Brake Charger/Bleeder Unit - VAS5234-
spec
es, in part or in w
♦ Engine Bung Set - VAS6122-
t to the co
♦ Adhesive Strip Remover - VAS6349-
♦ Sealing Plugs from the Repair Kit - 1H0 698 311 A-
rrectness of i
♦ Drill for example cordless drill or straight sander.
l purpos
nf
ercia
Note
orm
m
atio
m
First check the brake booster vacuum system in case of com‐

o
n in
c
plaints regarding the brake booster.

or
thi
e
⇒ “4.4 Vacuum System, Checking”, page 123

t
sd
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Component Location
en
ng
t.
yi Co
op
1 - ABS Hydraulic Unit - N55- and ABS Control Module - J104-
C py
t. rig
gh ht
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2 - Brake Booster
cop Vo
by lksw
cted agen
Prote AG.
Removing
– Remove the battery. Refer to ⇒ Electrical Equipment; Rep.
Gr. 27 ; Battery; Battery, Removing and Installing .
– Remove the engine cover. Refer to ⇒ Engine Mechanical,
Fuel Injection and Ignition; Rep. Gr. 10 ; Engine Cover; Engine
Cover, Removing and Installing .
Diesel Vehicles
Fuel Injection and Glow Plug; Rep. Gr. 23 ; Air Filter; Air Filter


Fuel Injection and Ignition; Rep. Gr. 24 ; Air Filter; Air Filter

– Remove the battery holder. Refer to ⇒ Electrical Equipment;
Rep. Gr. 27 ; Battery; Battery Tray, Removing and Installing .
transmission.
AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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ss c
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pt
du
an
itte
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erm
ab
ility
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wit
, is n
h re
– Remove the supply hose -2- for the clutch master cylinder
hole
spec
-3- from the brake fluid reservoir -4-.

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
– If equipped release the connector -2- from the Vacuum Sensor

do
priv
- G608- .
um
for
en
ng
t.
yi
– Release and remove the connector -3- from the Brake Fluid
Co
op py
Level Warning Switch - F34- .
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
and remove. Prote AG.
– Remove the vacuum in the brake booster by pressing the

brake pedal repeatedly.
– Remove the vacuum hose from the brake booster.

– Remove brake lines -A and B- from brake master cylinder.

Vehicles with DSG Transmission
– Remove the selector lever cable and cable bracket from the
transmission. Refer to ⇒ Direct Shift Gearbox; Rep. Gr. 34 ;
Selector Mechanism; Overview - Selector Mechanism .
– Remove the connector station and cable bracket from the . Volkswagen AG
transmission. Refer to ⇒ Manual Transmission; Rep. Gr. 34ks;wagen AG does
not
l
Selector Mechanism; Overview - Selector Mechanism .by Vo gu
a
ed ran
ris
Continuation for All Vehicles tho
tee
or
au ac
– Remove the side cover from the driver side ss
instrument panel.
ce
le
Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instrument Panel;

un
pt
an
d
Instrument Panel Side Cover, Removing and Installing .

itte
y li
erm
ab
ility
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wit
is n
h re
– Remove the driver side center console cover. Refer to ⇒ Body
ole,
spec
Interior; Rep. Gr. 68 ; Center Console; Center Console, Re‐
t to the co
– Remove the driver side storage compartment. Refer to ⇒
rrectne
ers .
– Remove the driver side instrument panel cover. Refer to ⇒
ss
o
cial p
f
ers; Driver Side Instrument Panel Cover, Removing and In‐
inform
stalling .
mer
atio
– Remove the knee airbag. Refer to ⇒ Body Interior; Rep. Gr.
om
n
69 ; Knee Airbags; Overview - Knee Airbag .
c
i
or
n thi
te
sd
– Remove the footwell vent on the driver side. Refer to ⇒ Heat‐
iva
o
r
ing, Ventilation and Air Conditioning; Rep. Gr. 87 ; Air Routing;

p
cum
r
fo
Overview - Air Routing and Air Distribution in Passenger Com‐ en

ng
t.
yi
partment .
Co
Cop py
t. rig
gh
– Remove the crash bolster. Refer to ⇒ Body Interior; Rep. Gr.
ht
pyri by
Vo
70 ; Instrument Panel Central Tube; Overview - Instrument
co lksw
by
cted agen
Panel Central Tube . Prote AG.
– Remove the Data Bus on Board Diagnostic Interface - J533-

and set aside. Refer to ⇒ Electrical Equipment; Rep. Gr. 97 ;
Control Modules; Data Bus On Board Diagnostic Interface -
J533- , Removing and Installing .
– Disconnect brake pedal from brake booster. Refer to
⇒ “4.2 Brake Pedal, Removing from Brake Booster”,
page 88 .

– Remove the bolt -1- and fold the footwell trim panel -2- in the
direction of the -arrow- into the vehicle interior.
– Remove the nuts -3 and 4- from the brake booster.

– Pull the brake booster from the plenum chamber against the
seal adhesiveness.
– Carefully remove the brake booster from the vehicle.
– Remove the master brake cylinder nuts.
– Remove any heat shield.
. Volkswagen AG
gen AG does
– Carefully remove the master brake cylinder from theVobrake
lksw
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booster. ed
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Installing utho eo
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ab
Note
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♦ The brake booster is only additionally glued with the seal at
h re
hole
the factory.
spec
es, in part or in w
♦ Do not replace the gluing on the brake booster and plenum
t to the co
chamber, but replace the seal.
rrectness of i
– Remove all adhesive residue from the plenum chamber and if
necessary the brake booster. To do this use Adhesive Strip
l purpos
Remover - VAS6349- with a dill for example a cordless drill or

straight sander.
nf
ercia
– Warm the adhesive residue gentle heat using a hot air gun and orm
remove.
m
atio
om
n in
– Let the Adhesive Strip Remover - VAS6349- run slowly and

or c
rub against the direction or travel.

thi
te
sd
iva
o
r
– Clean the surface thoroughly.

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ng
– Replace the seal -item 18- ⇒ Item 18 (page 107) .

t.
yi Co
Cop py
t.
– Carefully install the brake booster and tighten the nuts.
rig
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pyri by
Vo
co
– Attach the brake pedal to the brake booster. Refer to
by lksw
cted agen
Prote
AG.



– The seals -2- must be located in the return hose -1- to the
Bleeding .
♦ Refer to
106
♦ Refer to ⇒ Body Interior; Rep. Gr. 70 ; Instrument Panel Cen‐
tral Tube; Overview - Instrument Panel Central Tube .
wage es n
♦ Refer to ⇒ Heating, Ventilation and Air Conditioning; Rep. Gr. y Vo lks ot g
ua
87 ; Air Routing; Overview - Air Routing and Air Distributionisin ed
b ran
Passenger Compartment . uthor tee
or
a ac
ss
♦ Refer to ⇒ Body Interior; Rep. Gr. 69 ; Knee Airbags; Over‐
ce
le
view - Knee Airbag
un
pt
an
d
itte
y li
♦ Refer to ⇒ Body Interior; Rep. Gr. 68 ; Storage Compartments
rm
ab
and Covers; Component Location Overview - Storage Com‐
pe
ility
partment/Covers .
ot
wit
, is n
h re
♦ Refer to ⇒ Manual Transmission; Rep. Gr. 34 ; Selector
hole
spec
Mechanism; Overview - Selector Mechanism .
es, in part or in w
t to the co
♦ Refer to ⇒ Electrical Equipment; Rep. Gr. 97 ; Control Mod‐
ules; Data Bus On Board Diagnostic Interface - J533- , Re‐
rrectness of i
l purpos

Installing .
nform
ercia

m
a
com
tio
n in
r
te o
thi
s
iva
do
♦ Refer to ⇒ Electrical Equipment; Rep. Gr. 27 ; Battery; Over‐
r
rp
cum
view - Battery .
fo
en
ng
t.
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Cop py
3.5 Brake Fluid Reservoir, Removing and
t. rig
gh ht
pyri by
Installing
co Vo
by lksw
cted agen
Prote AG.

Removing
transmission.

– Remove the supply hose -2- for the clutch master cylinder
-3- from the brake fluid reservoir -4-.
Vehicles with Diesel Engine and 2.0L Gasoline Engine

– Remove the engine cover. Refer to ⇒ Engine Mechanical,AG. Volkswagen A
Fuel Injection and Ignition; Rep. Gr. 10 ; Engine Cover;
olks
waEngine
gen G do
es n
ot g
Cover, Removing and Installing . or ⇒ Engined Mechanical,
by
V ua
ran
Fuel Injection and Glow Plug; Rep. Gr. 10o;risEngine Cover;
e
tee
Engine Cover, Removing and Installing au th or
a
ss c
– Loosen hose clamps and remove the air guide hose and air
ce
le
un
pt
filter housing. Refer to ⇒ Engine Mechanical, Fuel Injection

an
d
itte
and Ignition; Rep. Gr. 24 ; Air Filter; Air Filter Housing, Re‐
y li
erm
ab

ility
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h re
ole,
spec

t to the co
– Release the connection -2- for the Brake Fluid Level Warning
Switch - F34- and remove.
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
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fo
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ng
t.
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Cop py
ht. rig
rig ht
by
119
copy Vo
by lksw
cted 3. Brake Booster/Brake Master Cylinder
agen
Prote AG.
wage es n
Golf 2015 ➤ , yGolf Vo Variant 2015 ➤
lks ot g
b ua
Brake Systemir se - Edition 12.2015
d ran
tee
tho
u or
a ac
– Release the
ss left and right catches -2- in direction of -arrow-
and remove the brake fluid reservoir from the sealing plug
ce
le
un
pt
upward.
an
d
itte
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rm
ab
pe
ility
ot
Note
wit
, is n
h re
hole
Lightly push the brake line aside.
spec
es, in part or in w
t to the co
Installing
rrectness of i
– Make sure the sealing plugs are seated correctly in the brake
l purpos
master cylinder -item 10- ⇒ Item 10 (page 107) .

– Coat the plugs with brake fluid before pushing the brake fluid
nform
ercia
reservoir into the master brake cylinder -item 10-

⇒ Item 10 (page 107) .
m
a
com
tio
n in
r
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thi
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iva
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r
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en
ng
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– The seals -2- must be located in the return hose -1- to the Cop py
t. rig
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co
by lksw
cted agen
Prote AG.
Bleeding .
♦ Refer to
106
Rep. Gr. 23 ; Air Filter; Air Filter Housing, Removing and In‐
stalling
Installing or ⇒ Engine Mechanical, Fuel Injection and Glow
Plug; Rep. Gr. 10 ; Engine Cover; Engine Cover, Removing
and Installing .

4 Vacuum System
⇒ “4.1 Overview - Vacuum Pump”, page 121
⇒ “4.2 Check Valve, Checking”, page 122
⇒ “4.3 Vacuum Sensor G608 , Removing and Installing”,
page 122
⇒ “4.4 Vacuum System, Checking”, page 123
4.1 Overview - Vacuum Pump

⇒ “4.1.1 Overview - Vacuum Pump, 2.0L Gasoline Engine”, page
121
⇒ “4.1.2 Brake Booster Vacuum Pump, Diesel Vehicles”,
page 121
4.1.1 Overview - Vacuum Pump, 2.0L Gasoline Engine
1 - Vacuum Hose
❑ Replace if damaged.
2 - Vacuum Line
❑ Replace if damaged.
3 - Seal
❑ Replace
4 - Vacuum Pump
❑ Refer to ⇒ Engine Me‐
chanical, Fuel Injection
and Ignition; Rep. Gr.
15 ; Cylinder Head;
Overview - Cylinder wage
es n
Head or ⇒ Engine Me‐ y Volks ot g
ua
chanical, Fuel Injectionised b ran
and Glow Plug; Rep.ut
hor tee
or
Gr. 15 ; Cylinder
ss Head;
a ac
Overview - Cylinder
ce
e
nl
Head .
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5 - Bolt
erm
ab
ility
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❑ 9 Nm
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spec
es, in part or in w
t to the co
rrectness of i
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om
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4.1.2 Brake Booster Vacuum Pump, Diesel

en
ng
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op
Vehicles
C py
t. rig
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The vacuum pump is installed behind the oil pump.
c by lksw
cted agen
Prote AG.
4. Vacuum System 121

– Vacuum Pump/oil pump removing and installing. Refer to ⇒

Engine Mechanical, Fuel Injection and Ignition; Rep. Gr. 17 ;
Oil Pan/Oil Pump; Overview - Oil Pan/Oil Pump or⇒ Engine
Mechanical, Fuel Injection and Glow Plug; Rep. Gr. 17 ; Oil
Pan/Oil Pump; Overview - Oil Pan/Oil Pump .
4.2 Check Valve, Checking

– Blow some air first in one then in the other direction through
the check valve.
♦ The check valve -A- must allow air to flow through in the di‐
rection of the -arrow-.
♦ The check-valve must remain closed for opposite direction. n AG. Volkswagen AG do
lkswage es n
Observe correct installation position! d byV
o ot g
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ran
ir se tee
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ss
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ility
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hole
spec
4.3 Vacuum Sensor - G608- , Removing
es, in part or in w
and Installing
t to the co
The Vacuum Sensor - G608- -2- is only installed on some gaso‐
rrectness of i
line engines.
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
riv
Removing
p
cum
for
en
ng
t.
– Disconnect the connector -1- from the Vacuum Sensor - G608-
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op
-2-.
C py
t. rig
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– Pull vacuum line out of brake booster. cop Vo
by lksw
cted agen
Prote AG.
– Unclip the Vacuum Sensor - G608- from the vacuum line.
Installing

4.4 Vacuum System, Checking

⇒ “4.4.2 Brake Servo Tester VAS6721 , Connecting”,
page 123
⇒ “4.4.3 Vacuum, Checking”, page 124 n AG. Volkswagen AG do
lkswage es n
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yV
⇒ “4.4.4 Leak Test”, page 125 sed b ua
ran
ir tee
ho
⇒ “4.4.5 Vacuum, Creating with
au Hand Vacuum Pump VAS6213 ”,
t or
ac
page 126 ss
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♦ Brake Servo Tester - VAS6721-
h re
hole
spec
The following checks will be helpful when performing “Fault Find‐
es, in part or in w
ing” if there are complaints regarding the brake booster or the so-
t to the co
called hard brake pedal.
The following components are included in the check:
rrectness of i
♦ Brake Booster
l purpos
♦ Seal between the master brake cylinder and the brake booster
♦ Check valve
nform
ercia
♦ Vacuum hoses and connectors

m
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com
tion in
♦ Vacuum pump (if equipped)
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te o
thi
The geographic location will influence the measurement results.
s
iva
do
r
The higher above sea level, the lower the air pressure.
rp
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fo
en
g
Observe test requirements:

n
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Cop py
.
♦ Check all the vacuum hoses for damage (for example, tears
t rig
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or damaged caused by animals) and make sure they are se‐ cop Vo
by lksw
cure cted agen
Prote AG.
♦ Maintain clean working conditions when working on the vac‐

uum system
♦ Clean the engine compartment before starting, if necessary
4.4.2 Brake Servo Tester - VAS6721- , Con‐

necting
– Remove the vacuum hose from the brake booster.
Pressing the brake pedal a few times beforehand makes it easier
to remove the vacuum hose.

. Volkswagen AG
gen AG does
swa
Golf 2015 ➤ , Golf y V Variant 2015 ➤
olk not
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b ara
Brake System ris - Edition 12.2015
ed
nte
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aut ra
– Connect thes Brake Servo Tester - VAS6721-
s c
ce
-see following illustrations-. le
un
pt
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Des‐ Com‐ Explanation
rm
ab
igna‐ po‐
pe
ility
tion nent
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A Shut- In direction toward the vacuum hose, the check
hole
spec
off valve and vacuum pump (if equipped)
es, in part or in w
valve
t to the co
B Shut- ♦ Opening the Brake Servo Tester - VAS6721-
off makes it easier to remove.
valve
rrectness of i
♦ Open to simulate an incorrect source
l purpos
♦ Connect the Hand Vacuum Pump - VAS6213- .
nform
ercia
C Shut- Toward the brake booster

off
m
a
valve
com
tion in
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thi
s
iva
– Connect the Brake Servo Tester - VAS6721- hose -A- to the
do
r
rp
c
vacuum hose.
um
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en
ng
t.
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– Push the adapter -C- into the brake booster.
Co
Cop py
ht. rig
rig ht
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by lksw
cted agen
Prote AG.
4.4.3 Vacuum, Checking
Note
♦ The average earth atmospheric air pressure at sea level (N.

N.) is 1,013 mbar (15 psi).
♦ At higher altitudes the air pressure decreases dramatically
(approximately 11 mbar (.2 psi) per 1,000 m (3,281 ft) altitude).
♦ Local and time fluctuations will influence the vacuum.
♦ A cold engine, the Air Conditioning (A/C) switched being on
and even only the engine idling can negatively influence the
vacuum.
– Check all the vacuum hoses beforehand for damage (for ex‐
ample, tears or damaged caused by animals) and make sure
they are secure
– Connect the Brake Servo Tester - VAS6721- . Refer to
page 123 .
– Open the shut-off valve -A-.

– Close the shut-off valves -B+C-.

– Start the warm (above 60 °C (140 °F)) engine and press the
accelerator pedal one time quickly (engine RPM
wage
n AG.higher
Volkswathan
gen AG
does
2,000). yV
olks not
gu b ara
ed
– Read the measured value displayed.
ho
ris nte
e
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Normally (see note) the vacuum
ss should be between 600 and 950
mbar (8.7 and 13.7 psi) (depending on the engine installed).
ce
e
nl
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an
itte
Check the vacuum system for leaks if the measured value is not
y li
erm
ab
reached, even though all requirements (see notes).
ility
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wit
– Create the vacuum using a Hand Vacuum Pump - VAS6213-
, is n
h re
for comparison purposes. Refer to
hole
⇒ “4.4.5 Vacuum, Creating with Hand Vacuum Pump
spec
es, in part or in w
VAS6213 ”, page 126 .
t to the co
Opening the shut-off valve -B- makes it easier to remove the hose
connections and the adapter.
rrectness of i
4.4.4 Leak Test
l purpos
nform
ercia
Note
m
at
om
io
♦ The average earth atmospheric air pressure at sea level (N.
n
c
in t
r
N.) is 1,013 mbar (15 psi).

o
his
ate
do
riv
♦ At higher altitudes the air pressure decreases dramatically

p
cum
or
(approximately 11 mbar (.2 psi) per 1,000 m (3,281 ft) altitude).

f
en
ng
t.
yi Co
♦ Local and time fluctuations will influence the vacuum. ht. Cop py
rig
rig ht
♦ A cold engine, the Air Conditioning (A/C) switched being on py by
co Vo
and even only the engine idling can negatively influence the
by lksw
cted agen
Prote
vacuum.
AG.
– Check all the vacuum hoses beforehand for damage (for ex‐
ample, tears or damaged caused by animals) and make sure
they are secure
– Connect the Brake Servo Tester - VAS6721- . Refer to
page 123 .
– Open the shut-off valve -A-.
– Close the shut-off valves -B+C-.
– Start the warm (greater than 60 °C (140 °F)) engine and press
the accelerator pedal one time quickly (engine RPM higher
than 2,000).
Normally (see note) the vacuum should be between 600 and 950
mbar (8.7 and 13.7 psi) (depending on the engine installed).

– Open the shut-off valve -C- and evacuate the brake booster.
– Turn off the engine.
– Read the measured value displayed and write it down.
The vacuum may drop 400 mbar (5.8 psi) within 12 hours.
If the vacuum drops more, check at the following points:
1- Brake Booster
2- Check valve, vacuum hoses and connections and vacuum
pump/intake manifold
The vacuum will drop considerably within a few seconds if there
are large leaks.
Checking the Vacuum Near the Brake Booster

– Close the shut-off valve -A- after creating the vacuum to test
the brake booster vacuum.
Note
Vacuum test near the check valve, vacuum hoses and connec‐
tions and vacuum pump/intake manifold.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
– Close the shut-off valve -C- after creating the vacuum to checkorise nte
the Brake Servo Tester - VAS6721- vacuum up to the intake auth eo
ra
manifold or up to the vacuum pump. ss c
ce
e
nl
pt
Opening the shut-off valve -B- makes it easier to remove the hose
du
an
itte
connections and the adapter.
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erm
ab
ility
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, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
4.4.5 Vacuum, Creating with Hand Vacuum
l purpos
Pump - VAS6213- nf
ercia
In certain situations, the vacuum can be created using a Hand

or
Vacuum Pump - VAS6213- instead of using the engine or a vac‐

m
m
atio
uum pump.
om
n in
or c
– Connect the Hand Vacuum Pump - VAS6213- to the vacuum

thi
e
hose on the connection -B- on the Brake Servo Tester -

t
sd
iva
VAS6721- .
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f
en
ng
– Open the shut-off valve -B-.

t.
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Cop py
– Create the vacuum using the Hand Vacuum Pump - VAS6213-
t. rig
gh ht
yri by
until a vacuum between 600 and 950 mbar (8.7 and 13.7 psi) cop Vo
by lksw
on the Brake Servo Tester - VAS6721- is displayed. cted agen
Prote AG.
– Perform the tests.

5 Brake Lines
⇒ “5.1 Brake Lines, Repairing”, page 127
5.1 Brake Lines, Repairing

⇒ “5.1.2 Overview - Flanging Tool”, page 129
⇒ “5.1.3 Instructions”, page 129

AG. Volkswagen AG d
agen oes
♦ Brake Line Tool Kit - VAS6056- olksw not
y V gu
d b ara
♦ Brake Charger/Bleeder Unit - VAS5234- rise nte
tho eo
au ra
Flare brake lines with 5 mm outer diameter using Brake
ss Line Tool c
Kit - VAS6056- without damaging coating. In this way, brake lines
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nl
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can be inexpensively partially replaced in certain cases.
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itte
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erm
ab
Working with Brake Line Kit - VAG1356- is not permitted because
ility
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of the coating and diameter of black brake lines.
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, is n
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hole
spec
Note
es, in part or in w
t to the co
♦ Do not bend the brake lines more than maximum 90°.
♦ Otherwise the lines will kink or otherwise deform.
rrectness of i
♦ From this the diameter of the line will be narrowed.
l purpos
♦ Disconnect brake lines preferably at underbody.
nf
ercia
♦ Position of intermediate pieces should be selected so that they
orm
cannot rub against moving parts.
m
atio
om
♦ Do not lubricate spindle, clean only with mineral spirits.
n in
or c
thi
te
sd
iva
List of Individual Tools
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Cop py
t. rig
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pyri by
Vo
co lksw
by
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Prote AG.
5. Brake Lines 127

1 - Brake Line Tool Kit - Flang‐

ing Tool - VAS6056/1-
❑ The Brake Line Tool Kit
- Flanging Tool -
VAS6056/1VAS
6056/6- the Clamp Jaws
- VAS6056/6- .
2 - Brake Line Tool Kit - Pipe
Cutter - VAS6056/2-
3 - Brake Line Tool Kit - Brake
Line Scraper - VAS6056/3-
❑ The threaded pins (in
shaft and at sides) are
set and must not be ad‐
justed!
4 - Brake Line Tool Kit - Line
Grips - VAS6056/4- AG. Volkswagen AG d
agen oes
olksw not
yV gu
5 - Brake Line Tool Kit - Pipe ed b ara
nte
is
Bending Tool - VAS6056/5- hor eo
aut ra
c
6 - AF 6 Angle Screwdriver ss
ce
e
nl
pt
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7 - Brake Line Tool Kit - Set Of
an
itte
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Clamp Jaws - VAS6056/7-
erm
ab
ility
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wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
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nf
ercia
orm
m
atio
om
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te
sd
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t.
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Cop py
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rig ht
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Prote AG.

5.1.2 Overview - Flanging Tool
1 - Flanging Tool Upper Sec‐

tion wage
es n
lks
❑ Remove to changed by Vo ot g
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Clamp Jaws o
ir se
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te
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2 - Hand Grip Mount
ss
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❑ Must be removed to
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reach the upper section
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retaining bolt
erm
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ility
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3 - Bolt
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❑ For flanging tool upper
h re
hole
section
spec
es, in part or in w
4 - Clamp Jaws Threaded Pins
t to the co
❑ Center and hold the
clamp jaws
rrectness of i
❑ 2 mm inner hex socket
l purpos
5 - Clamp Jaws
❑ Various
nf
ercia
o
❑ Assembly instructions.
rm
m
Refer to
atio
m
⇒ Fig. ““Clamp Jaws In‐

o
n in
c
stallation Instructions”“ ,
or
thi
e
page 129
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sd
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ng
t.
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Cop py
t. rig
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Clamp Jaws Installation Instructions

♦ VAS6056/6 (dark) for black brake lines
♦ VAS6056/7 (light) for green brake lines
Note
♦ The arrow on the rounded side of the clamp jaws must point
toward the edge of the housing.
♦ The straight side of the clamp jaws must be installed toward
the spindle, otherwise the flanged head will not be formed cor‐
rectly.
5.1.3 Instructions
– Remove the corresponding brake line on the brake caliper or
wheel brake cylinder.
– Be sure to catch any leaking brake fluid and dispose of it cor‐
rectly.
5. Brake Lines 129

– Cut the brake line at a suitable place (straight, easily accessi‐

ble piece) with the tube cutter -2-.
– Remove the piece to be exchanged.
– Lubricate brake line surface.
– Clamp the brake line in a set of locking pliers -4- so that 50

mm is sticking out of the plastic jaws.
– Install the peeling tool -3- in a power drill and place it on the
brake line.
– Shear coating from brake line at a slow drill RPM
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– Remove shearing tool from brake line and remove shavings.
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– Remove the locking pliers and push the tube fitting -D- onto
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– Push the brake line -B- against the stop -A- inside the flaring
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– Tension the brake line in the flanging tool.

– Push the brake line forward until it can no longer be moved.
– Fold up the stop -A-.
– Tighten the hex socket head bolts diagonally using a long
reach special wrench -C-.

– Turn the spindle all the way in the flange unit.

– Turn the spindle back.
– Loosen the hex socket head bolts diagonally.
– Remove the brake line from the flanging tool, clean the brake
line and the flared head and check.
Briefly rinse part of brake line remaining in vehicle:
– Connect the Brake Charger/Bleeder Unit - VAS5234- , place
the bleeder container hose on the flared head of the brake line
and run the Brake Charger/Bleeder Unit - VAS5234- briefly
until some brake fluid runs through.
– Clean the brake line with compressed air.
– Join brake lines with connecting piece -E-.

– Assemble brake line.
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5. Brake Lines 131

6 Hydraulic System
⇒ “6.1 Brake Fluid General Information”, page 132
⇒ “6.2 Hydraulic System, Standard Bleeding”, page 132
⇒ “6.3 Hydraulic System, Post-Bleeding”, page 133
⇒ “6.4 Checking for Leaks”, page 133
6.1 Brake Fluid General Information
WARNING
Only use new brake fluid conforming to VW standard (VW 501

14).
Note
♦ Brake fluid is poisonous. Due to its caustic nature, it must also

never come in contact with paint.
♦ Brake fluid is hygroscopic, meaning that it absorbs moisture
from the surrounding air, and must therefore be stored in air-
tight containers.
♦ Rinse any spilled brake fluid with plenty of water.
Brake Fluid, Changing

Refer to ⇒ Maintenance ; Booklet 36.1 ; Procedure Descriptions;
Brake and Clutch System, Changing Brake Fluid .
6.2 Hydraulic System, Standard Bleeding agen

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♦ Brake Charger/Bleeder Unit - VAS5234- auth eo
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♦ Brake Bleeding Tool Set - VAS6564-
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♦ The bleeding of hydraulic system using the Brake Charger/

h re
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Bleeder Unit - VAS5234- is described.

spec
♦ A positive pressure of 2 bar (29 psi) required to bleed the ABS

t to the co

rrectne
– Remove the rear wheels on vehicles with 15" rims.

Adhere strictly to work sequence when bleeding brake system.
ss o
– Connect the Brake Charger/Bleeder Unit - VAS5234-

cial p
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– Open the bleeder valves in the specified sequence and bleed

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the brake calipers.

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1- Front left brake caliper

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Use suitable bleeder hose. It must fit tightly on bleeder valve so

that no air gets into brake system.
– Vehicles with bleeder bottle hose attached, leave bleeder
valve open long enough that brake fluid exits without bubbles.
6.3 Hydraulic System, Post-Bleeding

Perform a post-bleeding when:
♦ The brake pedal travel is too long, or the so-called soft brake
pedal
A second technician is required during the post-bleeding.
– Connect the Brake Charger/Bleeder Unit - VAS5234-
– Press brake pedal forcefully and hold.
– Open bleeder valve at brake caliper.
– Press brake pedal down onto stop.
– Close bleeder valve with pedal depressed.
– Release brake pedal slowly.
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This bleeding procedure must be performed fivehor times per brake eo
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Bleeding sequence:
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3 - Left rear brake caliper
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4 - Right rear brake caliper
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A road test must be performed after bleeding. During this, at least

one ABS regulation must be performed! nform
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6.4 Checking for Leaks

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♦ Brake Pressure Gauge - VAG1310A-

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♦ Brake Pressure Gauge - Adapter M10 - VAG1310/6-

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Test Prerequisites ht. Cop py
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lines and brake calipers) operating properly and free of leaks.
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Checking
– Remove the bleeder valve at one front brake caliper.
– Attach and bleed the Brake Pressure Gauge - VAG1310A- .
– Apply pressure to brake pedal until the gauge indicates a
pressure of 50 bar (725 psi). The pressure must not drop by
more than 4 bar (58 psi) during the test period of 45 seconds.
Replace master cylinder if pressure drops greatly.
6. Hydraulic System 133

Golf 2015 ➤ , Golf Variant 2015 ➤ AG. Volkswagen AG d
Brake System - Edition 12.2015 agen oes
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♦ Brake Pressure Gauge - VAG1310A-
♦ Brake Pressure Gauge - Adapter M10 - VAG1310/6-


♦ Torque Wrench 1331 Insert - Ring Wrench - 11mm & 17mm -

VAG1331/2-
♦ Brake Line Kit - VAG1356-
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♦ Wiring Harness Repair Set - Hot Air Blower - VAS1978/14A-
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♦ Brake Line Tool Kit - VAS6056- in t

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♦ Hand Vacuum Pump - VAS6213-
7. Special Tools 135

♦ Adhesive Strip Remover - VAS6349-
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♦ Brake Bleeding Tool Set - VAS6564-
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♦ Brake Servo Tester - VAS6721-

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8 Revision History
DRUCK NUMBER: K0059241321
Fac‐ Edit Job Fe Notes Quality
tory Edi‐ Type ed‐ Checke
Edi‐ tion ba d By
tion ck
12.2 02/1 Fac‐ N/ Eric P.

015 1/20 tory A
16 Up‐
date
01.2 10/0 Lo‐ N/ (Rotors replaced in pairs per Tom
015 9/20 cal A axle) added until factory up‐ Perry
15 Up‐ date is provided
date
01.2 08/1 Edit‐ N/ Tom
015 8/20 ing A Perry
15 Re‐
view
01.2 08/1 Lo‐ 11 AU1 metadata removed Tom
015 0/20 cal 15 from two chapters that were Perry
15 Feed 33 blocked when viewing BX5
back 2 in ElsaPRo. Link changed to
correct chapter.
01.2 02/1 Lo‐ N/ updated ext-rl Eric P
015 3/20 cal A olkswage es n
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01.2 1/23/ Fac‐ N/ ss
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12/1 Fac‐ N/ Tom
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04/2 Fac‐ N/ Tom

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8. Revision History 137

Cautions & Warnings
Please read these WARNINGS and CAUTIONS before proceeding with maintenance
and repair work. You must answer that you have read and you understand these
WARNINGS and CAUTIONS before you will be allowed to view this information.
•= If you lack the skills, tools and equipment, or a suitable workshop for any procedure described in this manual, we
suggest you leave such repairs to an authorized Volkswagen retailer or other qualified shop. We especially urge
you to consult an authorized Volkswagen retailer before beginning repairs on any vehicle that may still be covered
wholly or in part by any of the extensive warranties issued by Volkswagen.
•= Disconnect the battery negative terminal (ground strap) whenever you work on the fuel system or the electrical
system. Do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy.
•= Volkswagen is constantly improving its vehicles and sometimes these changes, both in parts and specifications,
are made applicable to earlier models. Therefore, part numbers listed in this manual are for reference only. Always
check with your authorized Volkswagen retailer parts department for the latest information.
•= Any time the battery has been disconnected onwan AG. Volkswa
automatic gen AG
transmission
does vehicle, it will be necessary to
agen
ks
Vol
reestablish Transmission Control Moduleby(TCM) basic settings using the nVAG
ot g 1551 Scan Tool (ST).
u ara
ed nte
oris e
h
•= ut
Never work under a lifted vehicle aunless it is solidly supported on stands designed ofor
r a the
purpose. Do not support
s c
a vehicle on cinder blocks, hollow
s tiles or other props that may crumble under continuous load. Never work under a
ce
e
nl
vehicle that is supported solely by a jack. Never work under the vehicle while the engine is running.
pt
du
an
itte
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erm
ab
•= For vehicles equipped with an anti-theft radio, be sure of the correct radio activation code before disconnecting the
ility
ot p
battery or removing the radio. If the wrong code is entered when the power is restored, the radio may lock up and
wit
, is n
become inoperable, even if the correct code is used in a later attempt.
h re
hole
spec
•=
es, in part or in w
If you are going to work under a vehicle on the ground, make sure that the ground is level. Block the wheels to
t to the co
keep the vehicle from rolling. Disconnect the battery negative terminal (ground strap) to prevent others from
starting the vehicle while you are under it.
rrectness of i
•= Do not attempt to work on your vehicle if you do not feel well. You increase the danger of injury to yourself and
l purpos
others if you are tired, upset or have taken medicine or any other substances that may impair you or keep you from
being fully alert.
nform
ercia
•= Never run the engine unless the work area is well ventilated. Carbon monoxide (CO) kills.
m
at
om
ion
•= Always observe good workshop practices. Wear goggles when you operate machine tools or work with acid. Wear
c
in t
or
goggles, gloves and other protective clothing whenever the job requires working with harmful substances.
his
ate
do
priv
cum
or
•= Tie long hair behind your head. Do not wear a necktie, a scarf, loose clothing, or a necklace when you work near
f
en
ng
t.
machine tools or running engines. If your hair, clothing, or jewelry were to get caught in the machinery, severe op
yi Co
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injury could result. t. C rig
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•= Do not re-use any fasteners that are worn or deformed in normal use. Some fasteners are designed to be used Prote
cted AG.
agen
only once and are unreliable and may fail if used a second time. This includes, but is not limited to, nuts, bolts,
washers, circlips and cotter pins. Always follow the recommendations in this manual - replace these fasteners with
new parts where indicated, and any other time it is deemed necessary by inspection.
Page 1 of 3
© 2002 Volkswagen of America, Inc.
All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of
Volkswagen of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without
the prior expressed written permission of the publisher.
Version 1.0
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Cautions & Warnings
th or
au ac
ss
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nl
pt
•= Illuminate the work area adequately but safely. Use a portable safety light for working inside or under the vehicle.
du
an
itte
y li
Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled
erm
ab
fuel or oil.
ility
ot p
wit
, is n
h re
•= Friction materials such as brake pads and clutch discs may contain asbestos fibers. Do not create dust by
hole
spec
grinding, sanding, or by cleaning with compressed air. Avoid breathing asbestos fibers and asbestos dust.
es, in part or in w
Breathing asbestos can cause serious diseases such as asbestosis or cancer, and may result in death.
t to the co
•= Finger rings should be removed so that they cannot cause electrical shorts, get caught in running machinery, or be
crushed by heavy parts.
rrectness of i
l purpos
•= Before starting a job, make certain that you have all the necessary tools and parts on hand. Read all the
instructions thoroughly; do not attempt shortcuts. Use tools that are appropriate to the work and use only
nf
replacement parts meeting Volkswagen specifications. Makeshift tools, parts and procedures will not make good
ercia
or
repairs.
m
m
atio
om
n in
c
•= Catch draining fuel, oil or brake fluid in suitable containers. Do not use empty food or beverage containers that
or
thi
e
might mislead someone into drinking from them. Store flammable fluids away from fire hazards. Wipe up spills at
t
sd
iva
once, but do not store the oily rags, which can ignite and burn spontaneously.
o
r
rp
cu
o
m
f
en
ng
t.
yi
•= Use pneumatic and electric tools only to loosen threaded parts and fasteners. Never use these tools to tighten
Co
Cop py
fasteners, especially on light alloy parts. Always use a torque wrench to tighten fasteners to the tightening torque
t. rig
gh ht
yri by
listed. cop
by
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Prote AG.
•= Keep sparks, lighted matches, and open flame away from the top of the battery. If escaping hydrogen gas is
ignited, it will ignite gas trapped in the cells and cause the battery to explode.
•= Be mindful of the environment and ecology. Before you drain the crankcase, find out the proper way to dispose of
the oil. Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that
govern the disposal of wastes.
•= The air-conditioning (A/C) system is filled with a chemical refrigerant that is hazardous. The A/C system should be
serviced only by trained automotive service technicians using approved refrigerant recovery/recycling equipment,
trained in related safety precautions, and familiar with regulations governing the discharging and disposal of
automotive chemical refrigerants.
•= Before doing any electrical welding on vehicles equipped with anti-lock brakes (ABS), disconnect the battery
negative terminal (ground strap) and the ABS control module connector.
•= Do not expose any part of the A/C system to high temperatures such as open flame. Excessive heat will increase
system pressure and may cause the system to burst.
•= When boost-charging the battery, first remove the fuses for the Engine Control Module (ECM), the Transmission
Control Module (TCM), the ABS control module, and the trip computer. In cases where one or more of these
components is not separately fused, disconnect the control module connector(s).
•= Some of the vehicles covered by this manual are equipped with a supplemental restraint system (SRS), that
automatically deploys an airbag in the event of a frontal impact. The airbag is operated by an explosive device.
Handled improperly or without adequate safeguards, it can be accidentally activated and cause serious personal
injury. To guard against personal injury or airbag system failure, only trained Volkswagen Service technicians
should test, disassemble or service the airbag system.
Page 2 of 3
Version 1.0
Cautions & Warnings
•= Do not quick-charge the battery (for boost starting) for longer than one minute, and do not exceed 16.5 volts at the
battery with the boosting cables attached. Wait at least one minute before boosting the battery a second time.
•= Never use a test light to conduct electrical tests of the airbag system. The system must only be tested by trained
Volkswagen Service technicians using the VAG 1551 Scan Tool (ST) or an approved equivalent. The airbag unit
must never be electrically tested while it is not installed in the vehicle.
•= Some aerosol tire inflators are highly flammable. Be extremely cautious when repairing a tire that may have been
inflated using an aerosol tire inflator. Keep sparks, open flame or other sources of ignition away from the tire repair
area. Inflate and deflate the tire at least four times before breaking the bead from the rim. Completely remove the
tire from the rim before attempting any repair.
•= When driving or riding in an airbag-equipped vehicle, never hold test equipment in your hands or lap while the
vehicle is in motion. Objects between you and the airbag can increase the risk of injury in an accident.
I have read and I understand these Cautions and Warnings.
AG. Volkswagen AG d
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Page 3 of 3
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Service

Service Department. Technical Information

All rights reserved.

Copyright © 2016 Volkswagen AG, Wolfsburg D4B80416632

00 - General, Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

45 - Antilock Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4.6 Steering Angle Sensor G85 , Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.7 ABS Sensor Ring, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

1.1 Overview - Front Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

1.4 Brake Carrier, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

1.5 Brake Rotor, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2.2 Brake Pads, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

2.3 Brake Caliper, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

2.4 Brake Carrier, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

2.5 Brake Rotor, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

3.3 Rear Brake Cable, Removing and Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

4.4 Vacuum System, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

5 Brake Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

5.1 Brake Lines, Repairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

6 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

6.1 Brake Fluid General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

6.2 Hydraulic System, Standard Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

6.3 Hydraulic System, Post-Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

00 – General, Technical Data

1.1 Safety Precautions during Road Test

Distraction and unsecured testing equipment increase the risk

♦ The deployment of the front passenger airbag during an

accident can cause injury to the person.

1.2 Safety Precautions when Working on

Vehicles with Start/Stop System

Note the following When Working on Vehicles with a Start/Stop

There is a risk of injury due to the engine starting automatically

in vehicles with the Start/Stop System.

♦ If necessary, the engine can start automatically for vehi‐

cles with an active Start/Stop System.

♦ This is recognized by a message in the instrument cluster.

♦ Therefore, make sure that the Start/Stop System is deac‐

2.1 PR Number Allocation - Brakes

2.1.1 General Information

♦ For allocation. Refer to the Parts Catalog.

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

2.1.2 Front Brakes

PR Number Front Brakes

1ZE/1ZP PC57 (15”)

1ZB/1ZD/1LV PC57 (16”)

1LJ/1LM C60 (17”)

Rear Axle PR Number Rear Brakes

2 Rep. Gr.00 - General, Technical Data

3.1.1 Brake Master Cylinder and Brake Boos‐

ing on the engine instal‐ ches

Front Brakes PC57 (15”)

Item PR Number 1ZE/1ZP

Brake pad, wear mm 2

Front Brakes PC57 (16”)

Brake pad, wear mm 2

3 Brake rotor diam‐ 340

4 Brake caliper, diam‐ 60

4 Rep. Gr.00 - General, Technical Data

Front Brakes PC60 (17”):

3.1.3 Rear Brakes

3 Brake rotor diam‐ 272

Rear Brakes - PC 38 HRA Multi-Link Rear Axle

1 Brake Caliper TRW