Volkswagen Golf > VW Rabbit GTI 2006-> (A5)

Transcription

1 Volkswagen Golf > VW Rabbit GTI 2006-> (A5) Allocation of PR. No. for brakes The brake system installed in a vehicle is documented on the vehicle data sticker via the relevant PR number. Example of a vehicle data sticker: In this example the vehicle is equipped with the following brakes: Arrow 1 - rear brakes - 1KQ Arrow 2 - front brakes - 1ZE The vehicle data sticker is located in spare wheel well and in Maintenance booklet. Application Electronic Parts Catalog (ETKA) The following table explains PR numbers. This is important for brake caliper/brake disc and brake pads. Front brakes Engine version PR No. Front brakes 2.0l -110 kw 1ZP FN3 (15) 2.5L kw

2 Allocation of PR. No. for brakes Page 2 / L -147 kw FSI 1ZD / 1LV FN3 (16) Rear brakes Engine version PR No. Rear brakes 2.0l -110 kw 1KE CII 41 (15) 2.5L kw 1KF CII 41 (15) 2.0 L -147 kw FSI 1KV CII 38 (16)

3 Technical data, brakes Page 1 / Technical data, brakes Brake master cylinder and brake booster Brake master cylinder diameter in mm 22 Brake booster diameter in inches 10 Front wheel brakes Front brakes, FN 3 Item Pr.- No. 1ZE/1ZP 1 Brake caliper FN3 (15) 2 Brake pad, thickness mm 14 3 Brake disc diameter in mm 288 Brake disc, thickness mm 25 4 Brake caliper, piston diameter in mm 54 Item Pr.- No. 1LJ / 1LL / 1ZD / 1LV 1 Brake caliper FN3 (16) 2 Brake pad, thickness mm 14 3 Brake disc diameter in mm 312 Brake disc, thickness mm 25 4 Brake caliper, piston diameter in mm 54

4 Technical data, brakes Page 2 / 2 Rear brake (disc brake) Rear brake CII 41 Item Pr.- No. 1KF / 1KE 1 Brake caliper CII 41 (15) 2 Brake pad, thickness mm 11 3 Brake disc diameter in mm 260 Brake disc, thickness mm 12 4 Brake caliper, piston diameter in mm 41 Item Pr.- No. 1KJ 1 Brake caliper CII 41 (16) 2 Brake pad, thickness mm 11 3 Brake disc diameter in mm 286 Brake disc, thickness mm 12 4 Brake caliper, piston diameter in mm 41 Item Pr.- No. 2EL / 2EA 1 Brake caliper CII 41 (17) 2 Brake pad, thickness mm 11 3 Brake disc diameter in mm 310 Brake disc, thickness mm 22 4 Brake caliper, piston diameter in mm 41

5 General notes on anti-lock braking system (ABS) Page 1 / General notes on anti-lock braking system (ABS) The ABS brake system is divided diagonally. The servoassist is affected pneumatically by the vacuum brake servo unit. Models with ABS do not have a mechanical brake pressure regulator. A specially coordinated software program in the control module determines brake pressure allocation at the rear axle. Malfunctions of the ABS does not affect the brake system and the booster. Conventional brake system is not capable of ABS function. A change in braking behavior should be checked. When the ABS warning lamp comes on the rear wheels can lock-up early when braking! ABS allocation 1 - Hydraulic unit and control module 2 - Brake booster Control module and hydraulic unit comprise a single unit. Separation can only be performed when removed from vehicle. The hydraulic pump - 3-must not

6 General notes on anti-lock braking system (ABS) Page 2 / 2 be separated from the hydraulic unit. Separation is not possible on vehicles with ABS/EDL/ASR/ESP with hydraulic brake booster or hill assist.

7 Notes for repair work on Anti-lock Brake System Page 1 / Notes for repair work on Anti-lock Brake System Before performing repairs to the ABS, determine the cause of the malfunction via "Guided Fault Finding". "Guided fault finding" is performed with On Board Diagnosis, using the vehicle diagnosis, testing and information system VAS Disconnect negative Ground (GND) cable from the battery with the ignition off. Carry out before welding with an electric welding tool see Additional Information Body Collision Repair - General Information. Before welding operations using an electric welding tool, disconnect the ABS control module. When working with brake fluid, observe relevant safety precautions and notes 47-4, Bleeding braking system. After work for which the brake system had to be opened, bleed the brake system with brake filler and bleeder unit VAS , Bleeding braking system. During the final road test, ensure that a controlled brake test is performed at least once (pulsation must be felt at the brake pedal). Absolute cleanliness is required when working on the anti-lock brake system, it is not permitted to use any products which contain mineral oil, such as oils, greases etc. Thoroughly clean all unions and the adjacent areas before loosening, do not use aggressive cleaning agents such as brake cleaner, gasoline, thinners or similar.

8 Notes for repair work on Anti-lock Brake System Page 2 / 2 Place removed parts on a clean surface and cover. After separating the control module/hydraulic unit, use transport protection for valve body. Carefully cover or seal open components if repairs cannot be carried out immediately. (Sealing plugs, use repair kit 1 H A) Do not use fluffy cloths. Remove replacement parts from packaging immediately prior to installation. Only use genuine packed parts. When the system is open do not work with compressed air and do not move the vehicle. During painting operations, the electronic control module can be exposed to a max. temperature of 95 C for only a short period, and to a maximum of 85 C for longer periods (approx. 2 hours). Make sure that no brake fluid enters plug connectors.

9 Connecting Vehicle Diagnostic, Testing and Information System VAS 5051 and selecti... Page 1 / Connecting Vehicle Diagnostic, Testing and Information System VAS 5051 and selecting functions Special tools, testers and auxiliary items required Vehicle diagnostic, test and information system VAS 5051 Diagnostic cable VAS 5051/1 or VAS 5051/3 Warning! During a test drive, the testing and measuring equipment must always be secured on the back seat. These devices may be operated only by a passenger during a test drive. - Connect diagnostic cable VAS 5051/1 or VAS 5051/3 to diagnostic connection.

10 Connecting Vehicle Diagnostic, Testing and Information System VAS 5051 and selecti... Page 2 / 2 - Switch on tester - arrow -. The tester is operational when it displays a picture of a car. - Switch on ignition. - Touch Guided Fault Finding on screen. - Select one after another: Brand Type Model year Version Engine code - Confirm entered data. Note: Wait until tester has checked all control modules installed in the vehicle. - Press Goto button and select "Function/component selection" function. - Select "Suspension" on display - Select "Brake system" on display - Select "01-On Board Diagnostic (OBD) capable system..." indicated on display. - Select on display "Anti-lock brake system...". - Select "function" indicated on display. Note: Now, all possible functions of Anti-lock Brake System (ABS) installed in vehicle are displayed. - Select desired function on display.

11 Electrical/electronic components and installation locations Page 1 / Electrical/electronic components and installation locations ABS Mark 70 (ABS/ASR) ABS control module J104 Location: On hydraulic unit on right side of engine compartment. Do not disconnect connector before successfully completing On Board Diagnostic (OBD). Switch ignition off before separating connector. Removing and installing 45-6, Control module and

12 Electrical/electronic components and installation locations Page 2 / 9 hydraulic unit, removing ABS Hydraulic Unit N55 Location: In engine compartment, right side The hydraulic unit consists of the following components: ABS hydraulic pump V64 Valve block (contains the in/outlet valves) ABS Hydraulic Pump V64 and valve block must not be separated from each other. Removing and installing 45-6, Control module and hydraulic unit, removing Brake Pad Wear Indicator Lamp K32 Location: In instrument cluster Function: 45-5, Malfunction displayed by warning lamps for level control system ABS Warning Lamp K47 Location: In instrument cluster Function: 45-5, Malfunction displayed by warning lamps for level control system Traction Control Indicator Lamp K86 Location: In instrument cluster Function: 45-5, Malfunction displayed by warning lamps for level

13 Electrical/electronic components and installation locations Page 3 / 9 control system Brake System Warning Lamp K118 Location: In instrument cluster Function: 45-5, Malfunction displayed by warning lamps for level control system Brake Light Switch F up to KW 45/05 Includes Brake Pedal Switch F47 Location: on brake pedal Removing, installing and adjusting 47-5, Brake Light Switch F from KW 45/05, removing and installing Brake Light Switch F from KW 45/05 Includes Brake Pedal Switch F47 Location: On brake master cylinder Removing and installing 47-5, Brake Light Switch F from KW 45/05, removing and installing ASR/ESP Button E256 Location: In center console Data Link Connector (DLC) Location: Cover in driver footwell Right Front ABS Wheel Speed

14 Electrical/electronic components and installation locations Page 4 / 9 Sensor G45 / Left Front ABS Wheel Speed Sensor G47 Can be checked in "Guided Fault Finding" using VAS 5051 Removing and installing 45-7, ABS system components on front axle, removing and installing Wheel bearing housing Wheel bearing/hub unit The ABS sensor ring is installed in wheel bearing Right Rear ABS Wheel Speed Sensor G44 / Left Rear ABS Wheel Speed Sensor G46 Removing and installing (Front Wheel Drive (FWD)) 45-7, ABS system components on rear axle, removing and installing Rear axle body with stub axle Wheel hub with wheel bearing The ABS sensor ring is installed in the wheel bearing ABS Mark 60 (ABS/EDL/ASR/ESP)

15 Electrical/electronic components and installation locations Page 5 / 9 Volkswagen Technical Site: огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi ABS control module J104 Location: At hydraulic unit on right side of engine compartment. Do not disconnect connector before successfully completing On Board Diagnostic (OBD). Switch ignition off before separating connector. Removing and installing 45-6, Control module and hydraulic unit, removing ABS Hydraulic Unit N55 Location: In engine compartment, right side

16 Electrical/electronic components and installation locations Page 6 / 9 The hydraulic unit consists of the following components: ABS Hydraulic Pump V64 Brake pressure sensor G201 Can be checked in "Guided Fault Finding" using VAS 5051 Valve block (contains in/outlet valves) The ABS Hydraulic Pump V64 and valve block must not be separated from one another Removing and installing 45-6, Control module and hydraulic unit, removing Brake Pad Wear Indicator Lamp K32 Location: In instrument cluster Function: 45-5, Malfunction displayed by warning lamps for level control system ABS Warning Lamp K47 Location: In instrument cluster Function: 45-5, Malfunction displayed by warning lamps for level control system ASR/ESP Control Lamp K155 Only on vehicles with ABS/EDS/ASR/ESP Location: In instrument cluster

17 Electrical/electronic components and installation locations Page 7 / 9 Function: 45-5, Malfunction displayed by warning lamps for level control system Brake System Warning Lamp K118 Location: In instrument cluster Function: 45-5, Malfunction displayed by warning lamps for level control system Brake light switch F and Brake pedal switch F47 Includes Brake Pedal Switch F47 Location: on brake pedal Removing, installing and adjusting 46-4, Brake light switch F up to KW 45/05, removing, installing and adjusting Brake Light Switch F from KW 45/05 includes Brake Pedal Switch F47 Location: On brake master cylinder Removing and installing 47-5, Brake Light Switch F from KW 45/05, removing and installing ASR/ESP Button E256 Only on vehicles with ABS/EDS/ASR/ESP Location: in center console

18 Electrical/electronic components and installation locations Page 8 / 9 ESP-Sensor Unit G419 Only on vehicles with ABS/EDS/ASR/ESP Location: Under front passenger seat Combined Transverse Acceleration Sensor G200, Rotation Rate Sensor G202 and Longitudinal Acceleration Sensor G251 Combined in one housing Removing and installing 45-8, ESP-sensor unit G419, removing and installing Data Link Connector (DLC) Component location: cover in driver footwell Steering Angle Sensor G85 Location: On steering column between steering wheel and steering column switch Removing and installing 45-8, Steering angle sensor G85, removing and installing Right Front ABS Wheel Speed Sensor G45 /Left Front ABS Wheel Speed Sensor G47 Removing and installing 45-7, ABS system components on front axle, removing and installing Wheel bearing housing Wheel bearing/hub unit The ABS sensor ring is

19 Electrical/electronic components and installation locations Page 9 / 9 installed in wheel bearing hub Right Rear ABS Wheel Speed Sensor G44 / Left Rear ABS Wheel Speed Sensor G46 Front wheel drive shown Can be checked in "Guided Fault Finding" using VAS 5051 Removing and installing (Front Wheel Drive (FWD)) 45-7, ABS system components on rear axle, removing and installing Wheel bearing housing Wheel bearing/hub unit The ABS sensor ring is installed in wheel bearing

20 Malfunction displayed by warning lamps for level control system Page 1 / Malfunction displayed by warning lamps for level control system Warning lamps Item Designation 1 Traction Control Indicator Lamp K86 ASR/ESP Control Lamp K155 2 Brake Pad Wear Indicator Lamp K32 3 ABS Warning Lamp K47 4 Brake System Warning Lamp K118 Brake Pad Wear Indicator Lamp K32 If Brake Pad Wear Indicator Lamp K does not switch off 3 seconds after the ignition is switched on or if it lights up when vehicle is driven, it could be caused by the following malfunctions: - a - Brake pads may be worn. Check front and rear axle brake pads/linings. Replace worn brake pads/linings. - b - There is a wiring malfunction. Electrical Wiring Diagrams, Troubleshooting and Component Locations binder ABS Warning Lamp K47 If ABS Warning Lamp K does not go out after the ignition is switched on and the test sequence is complete, it could be caused by the following errors:

21 Malfunction displayed by warning lamps for level control system Page 2 / 4 - a - Voltage supply is under 10 volts. - b - There is an ABS malfunction. Caution! The ABS system remains switched off during an ABS malfunction - b -, but the traditional brake system remains fully functional. - c - There was a temporary wheel speed sensor malfunction since the last vehicle start. In this case the ABS warning light will go out after the engine is restarted and the vehicle speed exceeds 20 km/h. - d - The connection from instrument cluster to ABS Control Module J104 is interrupted. Electrical Wiring Diagrams, Troubleshooting and Component Locations binder - e - The instrument cluster is faulty. ABS Warning Lamp K47 and Brake System Warning Lamp K118 If ABS Warning Lamp K goes out but Brake System Warning Lamp K lights up, the malfunctions causes may be: - a - Parking brake is engaged. - b - The brake fluid level is too low (warning lamp blinking). Three warning tones are audible after switching on ignition. - c - There is a malfunction in the wiring to Brake System Warning Lamp K118. Electrical Wiring Diagrams, Troubleshooting and Component Locations binder If ABS Warning Lamp K and Brake System Warning Lamp K lights up, ABS system is malfunctioning. A change in braking behavior should be checked. Warning! After the ABS warning lamp K47 and brake system warning lamp K118 lights up, it is possible that the rear wheels will lock-up early. Traction Control Indicator Lamp K86

22 Malfunction displayed by warning lamps for level control system Page 3 / 4 If Traction Control Indicator Lamp K does not go out after ignition is switched on and test sequence is complete, malfunction may be: There is a malfunction present which only affects the ASR. The ABS and EBD safety systems are still completely functional check DTC memory. - a - Short to positive (+) in ASR/ESP Button E b - A malfunction in activation of Traction Control Indicator Lamp K86 Electrical Wiring Diagrams, Troubleshooting and Component Locations binder - c - ASR system was switched off by ASR/ESP Button E256 If Traction Control Indicator Lamp K86 blinks while driving, ASR system is operating in regulated mode. If the Traction Control Indicator Lamp K does not light up during the self test, the malfunction may be: - a - The Traction Control Indicator Lamp K86 is faulty Perform electrical test. ASR/ESP Control Lamp K155 If the ASR/ESP Control Lamp K does not turn off after the ignition is switched on and the test sequence is completed, the malfunction may be: There is a malfunction present which only affects the ASR/ESP. The ABS/EDL and EBD safety systems are still completely functional check DTC memory. - a - Short circuit to B+ in ASR/ESP Button E b - A malfunction in the actuation of ASR/ESP Control Lamp K155 Electrical Wiring Diagrams, Troubleshooting and Component Locations binder. - c - ASR/ESP system was switched off by ASR/ESP Button E256 If ASR/ESP Control Lamp K155 flashes while driving, the ASR or ESP systems are regulating the system. If the ASR/ESP Control Lamp K does not light up during the self test, the malfunction may be:

23 Malfunction displayed by warning lamps for level control system Page 4 / 4 - a - The ASR/ESP Control Lamp K155 is faulty Perform electrical test.

24 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 1 / Hydraulic unit, brake booster/brake master cylinder, assembly overview ABS Mark 70 (ABS/ASR) ABS control module J104 Removing and installing 45-6, Control module and hydraulic unit, removing ABS Hydraulic Unit N55 Removing and installing 45-6, Control module and hydraulic unit, removing Brake line

25 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 2 / 25 Brake master cylinder/primary piston circuit to hydraulic unit Identification: Tube fitting with threads M 10 x 1 Brake line Brake master cylinder/secondary piston circuit to hydraulic unit Identification: Tube fitting with threads M 12 x 1 Brake line To left front brake caliper Identification: Tube fitting with threads M 12 x 1 Brake line To right front brake caliper Identification: Tube fitting with threads M 10 x 1 Brake line To left rear brake caliper Identification: Tube fitting with threads M 12 x 1 Brake line To right rear brake caliper Identification: Tube fitting with threads M 10 x 1 Torx bolt, 5.5 Nm Use new bolts. Bracket

26 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 3 / 25 Hex head bolt, 8 Nm Gasket For brake booster Brake booster On gasoline engines the vacuum required is taken from the intake manifold. Functional check: - With engine switched off, depress brake pedal firmly several times (to exhaust the vacuum in the unit). - Depress brake pedal with average foot pressure, hold and start engine. If the booster unit is working properly, the pedal will be felt to give slightly under foot (booster assist becomes effective). If faulty, replace completely. Removing and installing 47-7, Brake booster, removing and installing Sealing ring Tandem brake master cylinder Application Electronic Parts Catalog (ETKA) Cannot be repaired. If faulty, replace completely. Removing and installing 47-6, Brake master cylinder, removing and installing Hex nut, 25 Nm Replace each time

27 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 4 / 25 Sealing plug Moisten with brake fluid and press into brake fluid reservoir Brake fluid reservoir Cap Sealing plug Connection for vacuum hose Connecting brake lines from tandem brake master cylinder to hydraulic unit On tandem master brake cylinder: A - Primary piston circuit of master brake cylinder to hydraulic unit - Identification: Tube fitting with threads M 10 x 1 B - Secondary piston circuit of master brake cylinder to hydraulic unit - Identification: Tube fitting with threads M 12 x Hydraulic unit to left front brake caliper 3 - Hydraulic unit to right rear brake caliper 4 - Hydraulic unit to left rear brake caliper

28 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 5 / 25 On hydraulic unit: A - Hydraulic unit to primary piston circuit of master brake cylinder - Identification: Tube fitting with threads M 10 x 1 B - Hydraulic unit to master cylinder secondary piston circuit - Identification: Tube fitting with threads M 12 x Hydraulic unit to left front brake caliper - Identification: Tube fitting with threads M 12 x Hydraulic unit to right front brake caliper - Identification: Tube fitting with threads M 10 x Hydraulic unit to right rear brake caliper - Identification: Tube fitting with threads M 10 x Hydraulic unit to left rear brake caliper - Identification: Tube fitting with threads M 12 x 1 Control module and hydraulic unit, removing

29 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 6 / 25 Special tools, testers and auxiliary items required Torque wrench V.A.G 1331 Torque wrench V.A.G 1410 Brake pedal actuator V.A.G 1869/2

30 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 7 / 25 Sealing plug repair kit, part no. 1H A After separating the control module from the hydraulic unit, the transport protection for valve body must be placed on the hydraulic unit. Warranties will not be granted for hydraulic units without transport protection. 1 - Transport protection for valve body (foam material) 2 - Sealing plug M Sealing plug M 12 Removing Location: The control module is bolted to the hydraulic unit and is located at right in the engine compartment. Caution! Do not bend the brake lines in the area of the hydraulic unit! - Read out and note the present control module coding. - Note or request radio code on vehicles with coded radio if necessary. - Disconnect battery

31 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 8 / 25 Repair Manual, Electrical Equipment, Repair Group 27, Batteries, disconnecting and connecting. - Remove engine cover. - Release control module connector in direction of - arrow 1 - and pull off Install brake pedal loading device V.A.G 1869/2. - Attach bleeder hose of bleeder bottles to left-front and left-rear brake caliper bleeder valves and open bleeder valves. - Operate brake pedal using brake pedal depressor V.A.G 1869/2 at least 60 mm. - Close left front and left rear bleeder valves. - Do not remove brake pedal loading device V.A.G 1869/2. - Place sufficient lint-free cloths under control module and hydraulic unit. Make sure that brake fluid does not come in contact with the terminals.

32 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 9 / 25 - Mark both brake lines from master cylinder - A and B - and remove from hydraulic unit. - Plug brake lines and threaded holes immediately with sealing plugs from repair kit Part No. 1H A. - Mark brake lines (brake caliper) - 1 to 4 -, remove and seal. - Pull hydraulic unit with control module upward out of shock absorbers. Unfastening control module from hydraulic unit - Set hydraulic unit with control module upward on to a clean, level surface.

33 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 10 / 25 - Remove Torx bolts - arrows -. - Pull control module off from hydraulic unit - arrow - without angling. - Carefully pull off all sealing rings from valve body of hydraulic unit. Caution! On a disconnected control module, circuit board is exposed. No moisture or particles of dirt must penetrate in the interior of control module. The hydraulic pump must not be separated from the hydraulic unit. - Cover the solenoid coils of control module with a lint-free

34 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 11 / 25 cloth. After separating the control module and hydraulic unit, use transport protection for valve body. Installing new control module Caution! Strong vibrations (e.g. falls, impacts) can destroy the control module. Control module must no longer be used. Surface must be cleaned before assembling. - Slide all sealing rings - A - slightly over valve dome. - Place control module without canting it on to hydraulic unit. Sealing rings are then brought into their end position. - Bolt hydraulic unit and control module with new inner Torx bolts supplied. Note: A new control module may be installed a max. of two times to a used hydraulic unit, to ensure that the elastic gasket seals sufficiently. A control module which was once in driving operation must not be installed a second time. Control module and hydraulic unit, installing Note: Remove sealing plugs on new hydraulic unit when

35 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 12 / 25 the corresponding brake line is going to be installed. If the sealing plugs are removed too early, brake fluid can escape, and can no longer be guaranteed that the unit is sufficiently filled or adequately bled. When installing, make sure that rubber installation pieces are not pressed out of console. - Installation is in reverse order of removal. - Remove brake pedal loading device V.A.G 1869/2. - Bleed braking system 47-4, Bleeding braking system - Enter radio code. - Perform ABS Control Module J104 coding with Vehicle Diagnosis, Testing and Information System VAS 5051 in "Guided Fault Finding". Torque specifications: Control unit to hydraulic unit 5.5 Nm Use new bolts! Hydraulic unit hex bolt to bracket Brake lines to ABS module: Thread M 10 x 1 Thread M 12 x 1 14 Nm 14 Nm 8 Nm ABS Mark 60 (ABS/EDL/ASR/ESP)

36 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 13 / 25 ABS control module J104 Separation from control module and hydraulic unit is not possible on vehicles with hydraulic brake booster or hill assist. Removing and installing 45-6, Control module and hydraulic unit, removing ABS Hydraulic Unit N55 Separation from control module and hydraulic unit is not possible on vehicles with hydraulic brake booster or hill assist. Removing and installing 45-6, Control module and

37 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 14 / 25 hydraulic unit, removing Brake line Brake master cylinder/primary piston circuit to hydraulic unit Identification: Diameter 6.5 mm and tube fitting with longer thread M12 x 1 Brake line Brake master cylinder/secondary piston circuit to hydraulic unit Identification: Diameter 6.5 mm and tube fitting with longer thread M12 x 1 Brake line To left front brake caliper Identification: Diameter 5.25 mm and tube fitting with shorter thread M12 x 1 Brake line To right front brake caliper Identification: Diameter 5.25 mm and tube fitting with thread M10 x 1 Brake line To left rear brake caliper Identification: Diameter 5.25 mm and tube fitting with shorter thread M12 x 1 Brake line To right rear brake caliper Identification: Diameter 5.25

38 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 15 / 25 mm and tube fitting with thread M10 x 1 Torx bolt, 5.5 Nm Use new bolts. Bracket Hex bolt, 8 Nm Gasket For brake booster Brake booster On gasoline engines the vacuum required is taken from the intake manifold. Some vehicles with a gasoline engine and automatic transmission are equipped with a vacuum pump for brakes 47-5, Brake system vacuum pump V192. On vehicles with HBV, a vacuum sensor is installed 45-8, Brake Booster Vacuum Sensor G483, removing and installing Functional check: - With engine switched off, depress brake pedal firmly several times (to exhaust the vacuum in the unit). - Depress brake pedal with average foot pressure, hold and start engine. If the booster unit is working properly, the pedal will be felt to give slightly under foot (booster assist becomes effective). If faulty, replace completely.

39 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 16 / 25 Removing and installing 47-7, Brake booster, removing and installing Sealing ring Brake Booster Vacuum Sensor G483 Only on vehicles with HBV Removing and installing 45-8, Brake Booster Vacuum Sensor G483, removing and installing Tandem brake master cylinder Application Electronic Parts Catalog (ETKA) Cannot be repaired. If faulty, replace completely. Removing and installing 47-6, Brake master cylinder, removing and installing Heat shield Hex nut, 25 Nm Replace each time Sealing plug Moisten with brake fluid and press into brake fluid reservoir Brake fluid reservoir Cap Sealing plug Connection for vacuum hose Vacuum hose

40 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 17 / 25 Insert into brake booster Connecting brake lines from tandem brake master cylinder to hydraulic unit On tandem brake master cylinder: A - Primary piston circuit of brake master cylinder to hydraulic unit - Identification: diameter 6.5 mm and tube fitting with thread M 12 x 1 B - Secondary piston circuit of brake master cylinder to hydraulic unit - Identification: diameter 6.5 mm and tube fitting with thread M 12 x Hydraulic unit to left front brake caliper 3 - Hydraulic unit to right rear brake caliper 4 - Hydraulic unit to left rear brake caliper On hydraulic unit: A - Hydraulic unit to primary piston circuit of brake master

41 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 18 / 25 cylinder - Identification: diameter 6.5 mm and tube fitting with longer thread M12 x 1 B - Hydraulic unit to master cylinder secondary piston circuit - Identification: diameter 6.5 mm and tube fitting with longer thread M12 x Hydraulic unit to left front brake caliper - Identification: diameter 5.25 mm and tube fitting with shorter thread M12 x Hydraulic unit to right front brake caliper - Identification: diameter 5.25 mm and tube fitting with thread M 10 x Hydraulic unit to right rear brake caliper - Identification: diameter 5.25 mm and tube fitting with thread M 10 x Hydraulic unit to left rear brake caliper - Identification: diameter 5.25 mm and tube fitting with shorter thread M12 x 1 Control module and hydraulic unit, removing

42 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 19 / 25 Special tools, testers and auxiliary items required Torque wrench V.A.G 1331 Torque wrench V.A.G 1410 Brake pedal actuator V.A.G 1869/2

43 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 20 / 25 Sealing plug repair kit, part no. 1H A After separating control module from the hydraulic unit, the transport protection for valve body must be placed on the hydraulic unit. Warranties will not be granted for hydraulic units without transport protection. 1 - Transport protection for valve body (foam material) 2 - Sealing plug M Sealing plug M 12 Removing Location: The control module is bolted to the hydraulic unit and is located at right side in the engine compartment. Caution! Do not bend the brake lines in the area of the hydraulic unit! - Read out and note the present control module coding. - Note or request radio code on vehicles with coded radio if necessary. - Disconnect battery

44 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 21 / 25 Repair Manual, Electrical Equipment, Repair Group 27, Batteries, disconnecting and connecting. - Remove engine cover. - Release control module connector in direction of arrow and pull off Install brake pedal loading device V.A.G 1869/2. - Attach bleeder hose of bleeder bottles to left-front and left-rear brake caliper bleeder valves and open bleeder valves. - Operate brake pedal using brake pedal depressor V.A.G 1869/2 at least 60 mm. - Close left front and left rear bleeder valves. - Do not remove brake pedal loading device V.A.G 1869/2. - Place sufficient lint-free cloths under control module and hydraulic unit. Make sure that brake fluid does not come in contact with the terminals.

45 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 22 / 25 - Mark both brake lines from master cylinder - A and B - and remove from hydraulic unit. - Plug brake lines and threaded holes immediately with sealing plugs from the repair kit Part No. 1H A. - Mark brake lines (brake caliper) - 1 to 4 -, remove and seal. - Pull hydraulic unit with control module upward out of dampers. Unfastening control module from hydraulic unit Note: Separation from control module and hydraulic unit is not possible on vehicles with hydraulic brake booster or hill assist. - Set hydraulic unit with control module downward on to a clean, level surface. - Remove Torx bolts E 5 - arrows - from hydraulic pump. Caution! The hydraulic pump must not be separated from the

46 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 23 / 25 hydraulic unit. - For this reason, secure hydraulic pump to hydraulic unit using the red bracket from replacement part set and two sealing plugs Carefully separate hydraulic unit with hydraulic pump upward at interface from control module. When removing control module, be sure that the valve domes of the hydraulic unit do not jam or get bent in the magnetic coils of the control module. Adapter for pump motor. - Cover solenoid coils of control module with a lint-free

47 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 24 / 25 cloth. After separating control module and hydraulic unit, use transport protection for valve body. Installing new control module Caution! Strong vibrations (e.g. falls, impacts) can destroy the control module. Control module must no longer be used. Before new control module can be assembled, pump motor adapter must first be inserted until it stops and engages. Adapter guide must not be damaged. The adapter supplied as replacement part for control module can be engage only once and then must not be separated again. The white grouting compound on base of control module serves as a seal and must not be removed. All contact surfaces on adapter, pressure sensor and control module as well as silicon gel and sealing elements must not be touched by hand or objects, soiled or damaged. - Press adapter into adapter guide until it stops, it must then be engaged. - Place control module without canting it on to hydraulic unit. - Bolt hydraulic unit and control module with new Torx bolts supplied. Note: A new control module may be installed a max. of two times to a used hydraulic unit, to ensure that the elastic gasket seals sufficiently. A control module which was once in driving operation must not be installed a second time. Control module and hydraulic unit, installing

48 Hydraulic unit, brake booster/brake master cylinder, assembly overview Page 25 / 25 Note: Remove sealing plugs on new hydraulic unit when the corresponding brake line is going to be installed. If the sealing plugs are removed too early, brake fluid can escape, and can no longer be guaranteed that the unit is sufficiently filled or adequately bled. - Installation is in reverse order of removal. - Remove brake pedal loading device V.A.G 1869/2. - Bleed braking system 47-4, Bleeding braking system - Enter radio code. - Code control module J104. Code control module using VAS 5051 via "Guided fault finding" function. A Steering Angle Sensor G85, Transverse Acceleration Sensor G200 and Brake Pressure Sensor 1 G201 basic setting must be done. Torque specifications: Control module to hydraulic unit 5.5 Nm Use new bolts! Hydraulic unit hex bolt to bracket Brake lines to ABS module: Thread M 10 x 1 Thread M 12 x 1 14 Nm 14 Nm 8 Nm

49 ABS system components on front and rear axles, removing and installing Page 1 / ABS system components on front and rear axles, removing and installing ABS system components on front axle, removing and installing ABS wheel speed sensor Before inserting sensor, clean inner surface of bore hole and coat with hot bolt paste G A3 Removing and installing 45-7, Speed sensor on front axle, removing and installing Hex socket head screw, 8 Nm

50 ABS system components on front and rear axles, removing and installing Page 2 / 4 Wheel bearing/hub unit The ABS sensor ring is installed in wheel bearing Drive axle Speed sensor on front axle, removing and installing Removing - Raise vehicle. - Separate speed sensor and speed sensor wiring connector Remove bolt from wheel bearing housing. - Remove ABS speed sensor from wheel bearing housing. Installing - Before inserting speed sensor, clean hole inner surface and coat speed sensor all-round with hot bolt paste G A3. - Insert speed sensor into hole in wheel bearing housing and tighten bolt to 8 Nm. - Connect speed sensor to speed sensor wiring. ABS system components on rear axle, removing and installing

51 ABS system components on front and rear axles, removing and installing Page 3 / 4 Volkswagen Technical Site: огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi ABS wheel speed sensor Before inserting sensor, clean inner surface of bore hole and coat with hot bolt paste G A3 Removing and installing 45-7, Speed sensor on rear axle, removing and installing Hex socket head bolt, 8 Nm Wheel bearing/hub unit The ABS sensor ring is installed in the wheel bearing

52 ABS system components on front and rear axles, removing and installing Page 4 / 4 Speed sensor on rear axle, removing and installing Removing - Raise vehicle. - Separate speed sensor and speed sensor wiring connector Remove bolt from wheel bearing housing. - Remove ABS speed sensor from wheel bearing housing. Installing - Before inserting speed sensor, clean hole inner surface and coat speed sensor all-round with hot bolt paste G A3. - Insert speed sensor into hole in wheel bearing housing and tighten bolt to 8 Nm. - Connect speed sensor to speed sensor wiring.

53 ESP system components, removing and installing Page 1 / ESP system components, removing and installing ESP-sensor unit G419, removing and installing The Transverse Acceleration Sensor G200, Rotation Rate Sensor G202 and Longitudinal Acceleration Sensor G251 are installed in a housing under passengers seat. After replacing ESP Sensor Unit G419, a Transverse Acceleration Sensor G200 basic setting must be performed. Caution! Strong vibrations (e.g. falls, impacts) can destroy the ESP Sensor Unit G419. ESP Sensor Unit G419 must then no longer be used. Removing - Remove passenger seat. Repair Manual, Body Interior, Repair Group 72, - Remove sill panel trim Repair Manual, Body Interior, Repair Group 68, Sill panel trim. - Lift carpet, remove bracket and lift floor covering. - Disconnect connector from ESP Sensor Unit

54 ESP system components, removing and installing Page 2 / 6 G Remove two mounting nuts - arrows -. - Remove ESP Sensor Unit G419. Installing - Installation is in reverse order of removal. When installing ESP Sensor Unit G419, be sure it is properly seated on the bracket and is free of tension. Note: Do not use the securing nuts to forcibly position the ESP Sensor Unit G Tighten securing nuts to 9 Nm. - Perform Transverse Acceleration Sensor G200 basic setting. VAS 5051, connecting and selecting functions 45-3, Connecting Vehicle Diagnostic, Testing and Information System VAS 5051 and selecting functions. ESP-sensor unit G419, removing and installing The Transverse Acceleration Sensor G200, Rotation Rate Sensor G202 and Longitudinal Acceleration Sensor G251 are installed in a housing under passengers seat. After replacing ESP Sensor Unit G419, a Transverse Acceleration Sensor G200 basic setting must be performed. Caution! Strong vibrations (e.g. falls, impacts) can destroy the ESP Sensor Unit G419. ESP Sensor Unit G419 must then no longer be used. Removing - Remove passenger seat. Repair Manual, Body Interior, Repair Group 72, - Remove sill panel trim

55 ESP system components, removing and installing Page 3 / 6 Repair Manual, Body Interior, Repair Group 68, Sill panel trim. - Lift carpet and lay it aside. - Remove connector station Raise floor covering. - Disconnect connector from ESP Sensor Unit G Remove two mounting nuts - arrows -. - Remove ESP Sensor Unit G419. Installing - Installation is in reverse order of removal. When installing ESP Sensor Unit G419, be sure it is properly seated on the bracket and is free of tension. Note: Do not use the securing nuts to forcibly position the

56 ESP system components, removing and installing Page 4 / 6 ESP Sensor Unit G Tighten securing nuts to 9 Nm. - Perform Transverse Acceleration Sensor G200 basic setting. VAS 5051, connecting and selecting functions 45-3, Connecting Vehicle Diagnostic, Testing and Information System VAS 5051 and selecting functions. Brake Booster Vacuum Sensor G483, removing and installing Removing - Battery, removing and installing Repair Manual, Electrical Equipment, Repair Group 27, Batteries, removing and installing. - Remove battery carrier. - Disconnect harness connector from Brake Booster Vacuum Sensor G Insert a screwdriver between stop and one end of securing ring into groove of sealing ring.

57 ESP system components, removing and installing Page 5 / 6 - Press securing ring as far out of groove until Brake Booster Vacuum Sensor G can be pulled out of brake booster. Installing - Installation is in reverse order of removal. Steering angle sensor G85, removing and installing Steering Angle Sensor G85 is installed between steering wheel and steering column switch. Removing and installing Repair Manual, Electrical Equipment;, Repair Group 94, Lights, Lamps, Switches - exterior; Steering column switch - Afterwards, basic setting of steering angle sensor G85 must be performed. VAS 5051, connecting and selecting functions 45-3, Connecting Vehicle Diagnostic, Testing and Information System VAS 5051 and selecting functions. Brake Booster Vacuum Sensor G483, removing and installing Removing - Battery, removing and installing Repair Manual, Electrical equipment, Repair Group 27, Batteries, removing and installing.

58 ESP system components, removing and installing Page 6 / 6 - Remove battery carrier. - Disconnect harness connector from Brake Booster Vacuum Sensor G Insert a screwdriver between stop and one end of securing ring into groove of sealing ring. - Press securing ring as far out of groove until Brake Booster Vacuum Sensor G can be pulled out of brake booster. Installing - Installation is in reverse order of removal.