00 - GENERAL, TECHNICAL DATA

Transcription

1 00 - GENERAL, TECHNICAL DATA BRAKES Brake System APPLICATION OF PR. NO. FOR BRAKES Application 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 Fig. 1: Example Of Vehicle Data Sticker In this example, the following brake system is installed in the vehicle: Arrow 1 - Rear brakes - 1KF Arrow 2 - Front brakes - 1LC The vehicle data sticker is located in spare wheel well and in Maintenance booklet. The following table shows the meaning of the PR numbers. These are important for combination brake caliper/brake disc/brake drum and brake pad. Front wheel brakes Engine version PR No. Front brakes 3.2L - 162, 177 kw 1LC/1LE Brembo (17") 3.6L -206 kw 4.2L kw 4.2L -257 kw 1LF Brembo (18")

2 5.0L kw TDI-PD Country-specific brakes for North America: Engine version PR No. Front brakes 4.2L -257 kw 1LE Brembo (17") Rear brakes (disc brakes) Engine version PR No. Rear brakes 3.2L - 162, 177 kw 1KF/1KQ Brembo (17") 3.6L -206 kw 4.2L kw 4.2L -257 kw 5.0L kw TDI-PD TECHNICAL DATA Brake master cylinder and brake booster Master brake cylinder Diameter in mm 26,99 Brake booster Diameter in 9/10-Dual inches Front wheel brakes FN 3 (16") front wheel brake

3 Fig. 2: FN 3 (16") Front Wheel Brake Item Pr.- No. 1LB 1 Brake caliper FN 3 (16") 2 Brake pad, thickness mm 12,5 3 Brake disc Diameter in mm 308 Brake disc, thickness mm 29,5 4 Brake caliper, pistons Diameter in mm 60 Front brakes, Brembo (17")

4 Fig. 3: Front Brakes, Brembo (17") - PR No: 1LC PR No: 1LC Item Pr.- No. 1LC 1 Brake caliper Brembo (17") 2 Brake pad, thickness mm 11 3 Brake disc Diameter in mm 330 Brake disc, thickness mm 32 4 Brake caliper, pistons Diameter in mm 2 x 34 2 x 36 2 x 38

5 Fig. 4: Front Brakes, Brembo (17") - PR No: 1LE PR No: 1LE Item Pr.- No. 1LE 1 Brake caliper Brembo (17") 2 Brake pad, thickness mm 11 3 Brake disc Diameter in mm 330 Brake disc, thickness mm 32 4 Brake caliper, pistons Diameter in mm 4 x 46 Brembo (18") front wheel brake

6 Fig. 5: Brembo (18") Front Wheel Brake Rear wheel brakes Item Pr.- No. 1LF 1 Brake caliper Brembo (18") 2 Brake pad, thickness mm 11 3 Brake disc Diameter in mm 350 Brake disc, thickness mm 34 4 Brake caliper, pistons Diameter in mm 2 x 30 2 x 34 2 x 38 Rear wheel brake (disc brake) 16"

7 Fig. 6: FN 3 (16") Front Wheel Brake Item Pr.- No. 1KE 1 Brake caliper FN 44 (16") 2 Brake pad, thickness mm 13 3 Brake disc Diameter in mm 314 Brake disc, thickness mm 22 4 Brake caliper, pistons Diameter in mm 44 Rear brakes (disc brakes 17")

8 Fig. 7: Rear Brakes (Disc Brakes 17") - PR No: 1KF PR No: 1KF Item Pr.- No. 1KF 1 Brake caliper Brembo (17") 2 Brake pad, thickness mm 11 3 Brake disc Diameter in mm 330 Brake disc, thickness mm 28 4 Brake caliper, pistons Diameter in mm 2 x 28 2 x 30

9 Fig. 8: Rear Brakes (Disc Brakes 17") - PR No: 1KQ PR No: 1KQ Item Pr.- No. 1KQ 1 Brake caliper Brembo (17") 2 Brake pad, thickness mm 11 3 Brake disc Diameter in mm 330 Brake disc, thickness mm 28 4 Brake caliper, pistons Diameter in mm 2 x 44 Parking brake (drum brake) 16"

10 Fig. 9: Parking Brake (Drum Brake) 16" Item 1 Parking brake drum Diameter in mm Parking brake pad, width mm 30 Parking brake pad, total thickness mm 5.5 Parking brake (drum brake) 17"

11 Fig. 10: Parking Brake (Drum Brake) 17" BRAKE TEST General information Item 1 Parking brake drum Diameter in mm Parking brake pad, width mm 30 Parking brake pad, total thickness mm 5,5 The wheels are driven by the test stand. When testing, place selector lever in driving position N for vehicles with automatic transmission and in neutral position for vehicles equipped with manual transmission. Follow instructions issued by manufacturer of brake test equipment. NOTE: Electronic brake control systems are inoperative when the ignition is switched off. Test Brake test must be performed on a regulated brake test stand driven in opposite directions. Moving in opposite directions means: The rollers on the brake test stand turn forward on the one side and backward on the other side. Regulated means: The speed of the test stand rollers must be regulated in such a way as to avoid any speed difference during the brake test. That prevents the braking force from being transmitted to the drivetrain. The wheel that is turning forward is measured during the test, which makes two brake tests per axle necessary. Test speed must not exceed 6 km/h. The Volkswagen approved test stand meets these requirements ANTI-LOCK BRAKE SYSTEM GENERAL NOTES ON ANTI-LOCK BRAKING SYSTEM (ABS) For ABS Mark 25, the following version is installed in the vehicle:

12 ABS/EDL/ASR with electronic stabilization program (ABS/EDL/ASR/ESP) The ABS brake system is divided diagonally (two circuits). The vacuum brake servo unit boosts the brakes pneumatically. ABS system malfunctions influence the brake system including boost assist. Changes in braking behavior should be checked. When the ABS warning lamp is lit up, the wheels may lock during braking! Vehicles with ABS Mark 25 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. Fig. 11: Identifying Control Module, Hydraulic Unit And Hydraulic Pump Control module and hydraulic unit comprise a single unit. Separation can only be performed when removed from vehicle. The hydraulic pump must not be separated from the hydraulic unit. New control modules via the replacement parts service are not coded. Modules must be coded following installation. Code control module using: VAS 5051 via "Guided fault finding" function. Fig. 12: ABS Layout In Left-Hand Drive Vehicle

13 ABS layout in left-hand drive vehicle. NOTES FOR REPAIR WORK ON ABS Notes for repair work on ABS Before performing repairs to the ABS, determine the cause of the malfunction via "Guided Fault Finding". "Guided Fault Finding" is performed using Vehicle Diagnosis, Testing and Information System VAS Before working on the ABS, disconnect the battery ground (GND) strap. Note radio code (for vehicles equipped with coded anti theft radio), determine if necessary. Before welding with an electric welding tool reference welding information in. When working with brake fluid, observe relevant safety precautions and notes --> Bleeding braking system. After finishing any work that required opening the brake system, bleed the brake system using the Brake Charger/bleeder Unit VAS 5234 or Brake Pedal Actuator VAG 1869/2, --> Bleeding braking system. During final road test, carry out at least one ABS controlled braking operation (appropriate pulsations must be felt at 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, fuel, thinners or similar chemicals. Place parts that have been removed on a clean surface and cover. Carefully cover over opened components or seal, if repairs are not carried out immediately. (Use Plugs 1 H A ) Only use lint-free cloths. Unpack replacement parts only immediately prior to installation. Only use genuine packed parts. Do not work with compressed air and do not move vehicle while the system is open. Make sure that no brake fluid enters electrical connections. When painting, electronic control module can be exposed to a maximum temperature of. 95 C only briefly, and to a maximum of 85 C for longer periods (approx. 2 hours). CONNECTING VAS 5051 AND SELECTING FUNCTIONS Connecting VAS 5051 and selecting functions

14 Special tools, testers and auxiliary items required Fig. 13: VAS 5051 Vehicle Diagnosis, Testing and Information System Vehicle Diagnosis, Testing and Information System VAS 5051 Vehicle diagnosis, testing and information system Diagnostic cable VAS 5051/1 or VAS 5051/3 CAUTION: Test equipment must always be secured on the rear seat during a road test. These devices may be operated only by a passenger during a test drive. Fig. 14: Identifying Diagnostic Cable VAS 5051/1 Connector Or VAS 5051/3 To Data Link Connector (DLC) Connect Diagnostic Cable VAS 5051/1 connector or VAS 5051/3 to Data Link Connector (DLC) - arrow -.

15 Fig. 15: Identifying Volkswagen Tester VAS 5051, On Switch Switch on tester - arrow -. The tester is operational when it displays a picture of a car. Switch on ignition. Select Guided Fault Finding on screen. Select the following, one after another: Brand Type Model year Version Engine code Confirm the entered data. Wait until tester has checked all control modules installed in the vehicle. Press the Go to button and select the "Function/component selection" function. Select on display "Running gear" Select on display "Brake system" Select "01-On Board Diagnostic (OBD) capable system..." indicated on display. Select on display "Anti-lock brake system...". Select on display "Function". Now, all possible functions of Anti-lock Brake System (ABS) installed in vehicle are displayed. Select the desired function on display.

16 ELECTRICAL/ELECTRONIC COMPONENTS AND INSTALLATION LOCATIONS Electrical/electronic components and installation locations Fig. 16: Electrical/Electronic Components And Installation Locations 1 - ABS Hydraulic Unit N55 Component location: In plenum chamber, right side The hydraulic unit consists of the components: ABS Hydraulic Pump V64 Valve block (contains the in/outlet valves) The ABS Hydraulic Pump V64 and valve block must not be separated from one another

17 2 - ABS Control Module (w/edl) J104 Component location: At hydraulic unit on right side of plenum chamber. Do not disconnect electrical connector before successfully completing On Board Diagnostic (OBD). Switch the ignition off before disconnecting the electrical connector. 3 - Brake Pressure Sensor 1 G201 Component location: At brake master cylinder. Removing and installing --> Brake Pressure Sensor 1 G201, removing and installing 4 - Brake Booster Pressure Sensor G294 Only installed on vehicles with gasoline engine and automatic transmission Component location: In vacuum hose to brake booster Removing and installing --> Brake Booster Pressure Sensor G294, removing and installing 5 - Brake System Vacuum Pump V192 Only installed on vehicles with gasoline engine and automatic transmission Component location: In engine compartment, front right Removing and installing --> Brake System Vacuum Pump V192, removing and installing 6 - ASR/ESP Control Lamp K155 Component location: In the instrument cluster Function: --> Malfunction indication via indicator lamps for level control system 7 - ABS Warning Lamp K47 Component location: In the instrument cluster Function: --> Malfunction indication via indicator lamps for level control system 8 - Brake System Warning Lamp K118 Component location: In the instrument cluster Function: --> Malfunction indication via indicator lamps for level control system 9 - ASR/ESP Button E256 Component location: in center console

18 10 - ESP-Sensor Unit G419 Component location: Beneath center console Combined Transverse Acceleration Sensor G200, Rotation Rate Sensor G202 and Longitudinal Acceleration Sensor G251 Combined in one housing Observe installation instructions --> ESP Sensor Unit G419, removing and installing 11 - Steering Angle Sensor G85 Component location: On steering column between steering wheel and steering column switch Observe installation instructions --> Steering Angle Sensor G85, removing and installing 12 - Data Link Connector (DLC) Component location: cover in driver footwell Diagnostic connection 13 - Brake Light Switch F and Brake Pedal Switch F47 Removing and installing --> Brake Light Switch F and Brake Pedal Switch F47, removing and installing Vehicle from calendar week 48/06 do not have a brake light switch 14 - Right Front ABS Wheel Speed Sensor G45/Left Front ABS Wheel Speed Sensor G47 Replacing --> Speed sensor on front axle, removing and installing 15 - Wheel bearing/hub unit The ABS sensor ring is installed in the wheel bearing 16 - Right Rear ABS Wheel Speed Sensor G44/Left Rear ABS Wheel Speed Sensor G46 Replacing --> Speed sensor on rear axle, removing and installing 17 - Wheel bearing/hub unit The ABS sensor ring is installed in the wheel bearing Diagnostic connection

19 Fig. 17: Diagnostic Connection MALFUNCTION INDICATION VIA INDICATOR LAMPS FOR LEVEL CONTROL SYSTEM Malfunction indication via indicator lamps for level control system Fig. 18: Level Control System Warning Lamps Warning lamps ABS Warning Lamp K47 Item Designation 1 ASR/ESP Control Lamp K155 2 Brake Pad Wear Indicator Lamp K32 3 ABS Warning Lamp K47 4 Brake System Warning Lamp K118

20 Fig. 19: Level Control System Warning Lamps 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: a - Voltage supply is below 10 Volt b - There is a malfunction in the ABS The ABS system remains switched off during an ABS malfunction - b -, but the traditional brake system remains fully functional. c - Since the last time the vehicle was started there was a temporary speed sensor malfunction. In this case the ABS Warning Lamp K47 will go out after the engine is restarted and the vehicle speed exceeds 2.75 km/h. d - The connection from instrument cluster to ABS Control Module (w/edl) J104 is interrupted. --> Electrical Wiring Diagrams, Troubleshooting and Component Locations e - ABS Warning Lamp K47 is faulty

21 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 - The brake fluid level is too low. Three warning tones are audible after switching on the ignition. b - There is a malfunction in the wiring to Brake System Warning Lamp K118 --> Electrical Wiring Diagrams, Troubleshooting and Component Locations. 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. CAUTION: After ABS Warning Lamp K47 and Brake System Warning Lamp K118 light up, rear wheels may lock prematurely when braking. Fig. 21: Level Control System Warning Lamps 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 the ASR/ESP button. b - A short circuit to ground in ASR/ESP Control Lamp K155 activation.

22 c - The connection from instrument cluster to contact 31 of ABS Control Module (w/edl) J104 is interrupted. d - ASR/ESP was switched off by the ASR/ESP Button E256. If the ASR/ESP Control Lamp K155 blinks while driving, the ASR or ESP system is in regulating mode. Fig. 22: Level Control System Warning Lamps If the ASR/ESP Control Lamp K did not light up during self-test, the following malfunction is present: a - ASR/ESP Control Lamp K155 is faulty --> perform electrical test ABS Warning Lamp K47 and ASR/ESP Control Lamp K155 If the ABS warning light K and the ASR/ESP control lamp K do not turn off after the ignition is switched on and the test sequence is completed, the malfunction may be: a - The voltage supply for the ABS system is below 10 volts and the vehicle speed is less than 12 km/h --> Perform electrical test. b - A short circuit to positive in ASR/ESP Control Lamp K155 activation. - Short circuit to B+ in ASR/ESP Button E256.

23 Fig. 23: Level Control System Warning Lamps ABS Warning Lamp K47, Brake System Warning Lamp K118 and ASR/ESP Control Lamp K155 If ABS Warning Lamp K47-3 -, ASR/ESP Control Lamp K155, and Brake System Warning Lamp K do not go out, malfunction causes may be: a - The voltage supply for the ABS system is below 10 volts and the vehicle speed is less than 12 km/h --> Perform electrical test. b - There is a malfunction in the hydraulic control module; ABS system is therefore not operating. A change in braking behavior should be checked. The rear wheels can lock up when braking! c - There was a dynamic wheel speed sensor malfunction during the last driving period. In this case, the warning lamps automatically switch off after a new vehicle start once a speed of 2.75 km/h is exceeded. This requires that the malfunction does not occur again after the repair work and new test are performed. Fig. 24: Level Control System Warning Lamps

24 Brake System Warning Lamp K118 If the Brake System Warning Lamp K does not go out after switching the ignition on, the malfunction may be: a - Foot operated parking brake is engaged. - Switch for Brake System Warning Lamp K118 is malfunctioning or incorrectly adjusted. - There is a malfunction in the wire routing --> Perform electrical test. The parking brake switch also informs the ABS Control Module (w/edl) J104 whether the parking brake is set or not. When the parking brake pedal is set, the ESP control is negatively influenced. Fig. 25: Level Control System Warning Lamps 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 - The brake pads are worn. Check front and rear axle brake pads/linings. Replace worn brake pads/linings. b - There is a malfunction in the wire routing. --> Electrical Wiring Diagrams, Troubleshooting and Component Locations HYDRAULIC UNIT, BRAKE BOOSTER/MASTER BRAKE CYLINDER - ASSEMBLY OVERVIEW Hydraulic unit, brake booster/master brake cylinder - assembly overview

25 Fig. 26: Hydraulic Unit, Brake Booster/Master Brake Cylinder - Assembly Overview 1 - ABS Control Module (w/edl) J ABS Hydraulic Unit N Brake line Master brake cylinder/primary piston circuit to hydraulic control unit Identification at hydraulic unit - DK Brake line Master brake cylinder/secondary piston circuit to hydraulic unit Identification at hydraulic unit - SK -

26 5 - Brake line Via intermediate piece toward rear left brake caliper Marked on hydraulic unit with - HL Brake line Via intermediate piece toward front right brake caliper Marked on hydraulic unit with - VR Brake line To left front brake caliper Marked on hydraulic unit with - VL Brake line Via intermediate piece toward rear right brake caliper Marked on hydraulic unit with - HR Intermediate piece 10 - Bracket 11 - Flange bolt, 5 Nm 12 - Bolt, 8 Nm 13 - Buffer 14 - Gasket For brake booster 15 - Tandem brake booster On gasoline engines, vacuum is supplied from intake manifold. Vehicles with gasoline engine and automatic transmission are equipped with a brake system vacuum pump. On Diesel engines, a vacuum pump is installed for vacuum creation. Functional check: With engine switched off, depress brake pedal firmly several times (to deplete vacuum in tool). Depress and hold brake pedal with average foot pressure and start engine. If brake booster is working

27 29 - Torx bolts, 4 Nm 2006 Volkswagen Touareg Replace as a unit in the event of malfunction (previously, check all vacuum lines). Removing and installing --> Brake booster, removing and installing 16 - Sealing ring 17 - Brake Booster Membrane Position Sensor G420 Removing and installing --> Brake Booster Membrane Position Sensor G420, removing and installing 18 - Snap ring 19 - Seal Connection for vacuum hose 20 - Vacuum hose To brake booster 21 - Sealing ring 22 - Self-locking nut, 25 Nm Always replace after removal 23 - Brake Pressure Sensor 1 G201 Removing and installing --> Brake Pressure Sensor 1 G201, removing and installing 24 - Bracket 25 - Master brake cylinder Cannot be serviced. Replace as complete unit if malfunctioning. Removing and installing --> Brake master cylinder, removing and installing 26 - Seals Moisten with brake fluid and press into brake fluid reservoir 27 - Brake fluid reservoir 28 - Master Cylinder cap

28 Connection of brake lines from master brake cylinder to hydraulic unit Fig. 27: Connection Of Brake Lines From Master Brake Cylinder To Hydraulic Unit (1 Of 2) A - Hydraulic unit to primary piston circuit of master brake cylinder - Identification at hydraulic unit - DK - B - Hydraulic unit to master cylinder secondary piston circuit - Identification at hydraulic unit - SK Hydraulic unit to front left brake caliper - Marked on hydraulic unit with - VL Hydraulic via intermediate unit to front right brake caliper - Marked on hydraulic unit with - VR Hydraulic via intermediate unit to rear right brake caliper - Marked on hydraulic unit with - HR Hydraulic via intermediate unit to rear left brake caliper - Marked on hydraulic unit with - HL -

29 Fig. 28: Connection Of Brake Lines From Master Brake Cylinder To Hydraulic Unit (2 Of 2) ABS hydraulic control unit, removing and installing Special tools, testers and auxiliary items required Fig. 29: Torque Wrench V.A.G 1410 Torque Wrench VAG 1410

30 Fig. 30: Brake Pedal Depressor V.A.G 1869/2 Brake Pedal Actuator VAG 1869/2 Sealing Plug Repair Set 1H A Fig. 31: Sealing Plug Repair Set, Part No. 1H A After separating the control module from the hydraulic unit, always install transport protection on the hydraulic unit for the valve domes. Warranties will not be granted for hydraulic units without transport protection. 1 - Transport protection for valve domes (foam) 2 - Sealing plug M Sealing plug M 12 Component location: The control module is bolted to the hydraulic unit and is located to the right in the plenum chamber. CAUTION: Do not bend brake lines near the hydraulic unit!

31 Control module and hydraulic unit, removing Note or request radio code on vehicles with coded radio if necessary. Disconnect battery --> 27 - BATTERY, STARTER, GENERATOR, CRUISE CONTROL. Remove plenum chamber cover --> 64 - GLASS, WINDOWS. Remove engine control module. Remove the ground cable from the body, located behind engine control module bracket. Unclip cable harness and lay aside Remove engine control module bracket. Remove intake housing --> 87 AIR CONDITIONING. Fig. 32: Disengaging Connector From Control Module Disengage connector from control module in direction of arrow and disconnect (arrow - 2 -). Attach bleeder hose of bleeder bottle to left front brake caliper bleeder valve and open bleeder valve. Install Brake Pedal Actuator VAG 1869/2. Close front left bleeder valve. Place a lint-free cloths under the control module and hydraulic unit. Make sure that brake fluid does not come in contact with the terminals. Identify brake lines and remove at hydraulic unit and intermediate piece. Seal brake lines and threaded holes with Sealing Plug Repair Set 1H A.

32 Fig. 33: Removing Hydraulic Unit From Bracket Remove - arrows - hydraulic unit from bracket. Remove hydraulic unit upward together with control module. Control module, removing from hydraulic unit Place hydraulic unit with control module on a clean, level surface. Fig. 34: Removing External Torx Screws Remove external Torx screws - arrows -.

33 Fig. 35: Pulling Control Module Off From Hydraulic Unit Without Angling Pull control module off from hydraulic unit - arrow - without angling. CAUTION: Moisture and dirt particles must not penetrate the interior of control module. The hydraulic pump must not be separated from the hydraulic unit. Cover control module magnetic coils with a lint free cloth. After separating the control module and hydraulic unit, use transport protection for valve body. Assembling new control module CAUTION: Excessive shaking (e.g. dropping, impact) may destroy the control module. Control module must then no longer be used. Surface must be cleaned before assembling. Place control module without canting it on to hydraulic unit. Bolt hydraulic unit and control module with new inner Torx screws supplied. NOTE: A new control module may be installed a maximum of two times to a used hydraulic unit, to ensure that the elastic gasket seals sufficiently. A control module which was once in operation must not be installed a second time. Control module and hydraulic unit, installing NOTE: Do not remove sealing plugs from the new hydraulic unit until the corresponding brake line is about to be installed.

34 Installation is performed in the reverse order of removal. Remove Brake Pedal Actuator VAG 1869/2. Bleed brake system --> Bleeding braking system. Enter radio code. If the sealing plugs are removed too early, brake fluid can escape. If this occurs, unit may not be sufficiently filled or adequately bled. Perform ABS Control Module (w/edl) J104 coding using in "Guided Fault Finding". After replacing the ABS Control Module (w/edl) J104, also basic setting must be performed. Tightening torques Control module to hydraulic unit Hydraulic unit bolt to bracket Brake lines at ABS module: Thread M 10 x 1 Thread M 12 x 1 14 Nm 14 Nm max. 4 Nm 8 Nm ABS SYSTEM COMPONENTS ON FRONT AND REAR AXLES, REMOVING AND INSTALLING ABS system components on front and rear axles, removing and installing

35 Fig. 36: Identifying ABS Wheel Speed Sensor, Bolt, Wheel Hub With Wheel Bearing & Driveshaft 1 - ABS wheel speed sensor Before inserting sensor, clean inner surface of bore hole and coat with Polycarbamide Grease G A2 Removing and installing --> Speed sensor on front axle, removing and installing 2 - Bolt, 8 Nm 3 - Wheel hub with wheel bearing The ABS sensor ring is installed in the wheel bearing 4 - Driveshaft

36 Speed sensor on front axle, removing and installing Removing Raise vehicle. Fig. 37: Speed Sensor Wiring Connector & Bolt 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 wheel speed sensor, clean inner surface of bore/hole and coat sensor completely with Polycarbamide Grease G A2. 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

37 Fig. 38: Identifying ABS Wheel Speed Sensor, Bolt, Wheel Bearing/Hub Unit & Driveshaft 1 - ABS wheel speed sensor Before inserting sensor, clean inner surface of bore hole and coat with Polycarbamide Grease G A2 Removing and installing --> Speed sensor on rear axle, removing and installing 2 - Bolt, 8 Nm 3 - Wheel bearing/hub unit The ABS sensor ring is installed in the wheel bearing 4 - Driveshaft

38 Speed sensor on rear axle, removing and installing Removing Raise vehicle. Fig. 39: Identifying Speed Sensor Wiring Connector & Bolt 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 wheel speed sensor, clean inner surface of bore hole and coat sensor completely with Polycarbamide Grease G A2. Insert speed sensor into hole in wheel bearing housing and tighten bolt to 8 Nm. Connect speed sensor to speed sensor wiring. COMPONENTS OF ESP SYSTEM, 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 center console. After replacing ESP Sensor Unit G419, Transverse Acceleration Sensor G200 and Longitudinal Acceleration Sensor G251 basic setting must take place. CAUTION: Strong vibrations can destroy the Transverse Acceleration Sensor G200, Rotation Rate Sensor G202 and Longitudinal Acceleration Sensor G251. Removing

39 Remove center console --> 68 - INTERIOR EQUIPMENT. Remove the airbag control module and lay aside slightly toward front --> 69 - PASSENGER PROTECTION - AIRBAGS, SEAT BELTS. Fig. 40: Identifying Connector & Sensor Unit Mounting Nuts Disconnect connector from ESP Sensor Unit G419. Remove the two sensor unit mounting nuts - arrows -. Remove ESP Sensor Unit G419. Installing Installation is performed in the reverse order of removal. When installing ESP sensor unit, be sure it is properly seated on the bracket and free of tension. Never force ESP sensor unit into position using mounting nuts. Tighten the nuts to 8 Nm. Perform Transverse Acceleration Sensor G200 and Longitudinal Acceleration Sensor G251 basic setting. VAS 5051, connecting and selecting functions --> Connecting VAS 5051 and selecting functions. Steering Angle Sensor G85, removing and installing Steering Angle Sensor G85 is installed between steering wheel and steering column switch. Removing and installing --> 94 - LIGHTS, SWITCHES - EXTERIOR. Afterwards, basic setting of Steering Angle Sensor G85 must be performed.

40 Vehicle Diagnosis, Testing and Information System VAS 5051, connecting and selecting functions --> Connecting VAS 5051 and selecting functions BRAKES - MECHANICAL COMPONENTS FRONT BRAKES, SERVICING Front brakes, FN 3 (16") calipers, servicing NOTE: 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. Use brake charger/bleeder unit Brake Charger/bleeder Unit VAS 5234 or extraction device Extraction Device Upgrade Kit VAG 1869/4 to extract brake fluid from brake fluid reservoir. Before removing brake caliper or disconnecting brake hose, brake pedal actuator Brake Pedal Actuator VAG 1869/2 must be inserted (this dissipates pressure).

41 Fig. 41: Front Brakes, FN 3 (16") Calipers, Servicing Remove/Install Components 1 - Brake disc Internally ventilated brake disc: diameter 308 mm Brake disc thickness: 29.5 mm Wear limit: 25.5 mm Must always be replaced together on both sides of axle Remove brake caliper and brake carrier before removing 2 - Bolt, 15 Nm Brake disc to wheel hub

42 3 - Brake pads Thickness 11.5 mm without backing plate Wear limit: 2 mm without backing plate With wear indicator When wear limit is reached (limit: approx. 4 mm), the warning lamp lights up in instrument cluster Checking thickness --> 01 - MAINTENANCE Must always be replaced together on both sides of axle Removing and installing --> Brake pads, removing and installing 4 - Retaining spring Press under brake carrier and insert in both holes of brake caliper 5 - Brake caliper Do not remove brake hose when replacing brake pads or brake discs Removing and installing --> Brake caliper, removing and installing Servicing --> Brake caliper FN 3, servicing 6 - Guide pins, 30 Nm (18 ft lb) 7 - Cap 8 - Bracket for brake pad wear indicator wire 9 - Bolt, 10 Nm 10 - Brake carrier Bolt to wheel bearing housing 11 - Bolt, 270 Nm Always replace after removal 12 - Bracket 13 - Bolt, 9 Nm 14 - Brake hose, 14 Nm Do not remove when replacing brake pads or brake discs

43 Brake pads, removing and installing Special tools, testers and auxiliary items required Fig. 42: Torque Wrench V.A.G 1331 Torque Wrench 5-50nm VAG 1331 Fig. 43: Piston Resetting Tool T10145 Piston Resetting Tool T10145 Removing When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven! Remove wheels.

44 Fig. 46: Identifying Brake Pad Wear Indicator Connector, Dust Cap & Bracket 2006 Volkswagen Touareg Fig. 44: Pushing Retaining Spring Until It Can Be Pressed Out Of Hole Push retaining spring toward - direction of arrow A - until it can be pressed out of hole toward - direction of arrow B -. Fig. 45: Turning Retaining Spring Until It Can Be Removed From Upper Hole Turn retaining spring clockwise - arrow - until it can be removed from upper hole.

45 Disconnect the connector for brake pad wear indicator. Remove dust cap and remove brake pad wear indicator wire. Remove wire for the brake pad wear indicator from bracket at brake caliper. Fig. 47: Identifying Covers Remove covers - arrows -. Fig. 48: Removing Both Guide Pins From Brake Caliper Remove both guide pins - arrows - from brake caliper. Remove brake caliper and secure with wire so that the weight of the brake caliper does not burden or damage the brake hose. Remove brake pads. Cleaning: CAUTION: Do not use compressed air to clean brake dust, the dust produced is

46 Thoroughly clean contact surfaces for brake pads at brake carrier, remove corrosion. Clean brake calipers (remove adhesive reside) - contact surfaces must be dry and clean. Use only appropriate solvents for cleaning the brake caliper. Installing harmful to health! Before pressing pistons into cylinder using piston resetting tool, brake fluid must be extracted from brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage. Fig. 49: Pressing Pistons Back Using Piston Resetting Tool T10145 Press pistons back using Piston Resetting Tool T NOTE: The inner brake pads (piston side) have a predetermined running direction and are marked for this purpose.

47 Fig. 50: Identifying Right/Left Brake Pad, Piston Side & Position Directional brake pads 1 - Right brake pad, piston side 2 - Left brake pad, piston side When installed, arrow - A - on the backing plate of brake pad must point downward. Fig. 51: Inserting Brake Pad With Retaining Springs In Piston Insert brake pad with retaining springs in piston - arrows -. Remove protective foil on backing plate of outer brake pad.

48 Fig. 52: Installing Outer Brake Pad On Brake Carrier Install outer brake pad - A - on brake carrier. When installing brake caliper, make sure that brake pad is not affixed to brake caliper before the correct installation position has been reached. Fig. 53: Installing Brake Caliper To Brake Carrier Using Both Guide Pins Install brake caliper to brake carrier using both guide pins - arrows -. Install both protective caps.

49 Fig. 54: Identifying Brake Pad Wear Indicator Connector, Dust Cap & Bracket Connect brake pad wear indicator connector to the bracket on wheel bearing housing. Secure wire of brake pad wear indicator with dust cap to bleeder valve and bracket at brake caliper. Fig. 55: Inserting Retaining Spring In Upper Hole Insert retaining spring in upper hole - arrow - and rotate in the direction of the - arrow -. Attach retaining spring at lower brake carrier.

50 Fig. 56: Pushing Retaining Spring In First And Then Into Hole Of Brake Caliper At Same Time Push retaining spring in direction of - arrow A - first and then into hole of brake caliper at the same time direction of - arrow B -. Install wheels. Tightening torque specification for wheel bolts --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT NOTE: 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. Check brake fluid level after replacing brake pads. Brake caliper Tightening torque 30 Nm Brake caliper, removing and installing Special tools, testers and auxiliary items required Fig. 57: Torque Wrench V.A.G 1331

51 Torque Wrench 5-50nm VAG 1331 Fig. 58: Brake Pedal Depressor V.A.G 1869/2 Brake Pedal Actuator VAG 1869/2 Removing Work procedure applies only for replacing or when performing subsequent service work on brake caliper. Remove wheels. Fig. 59: Pushing Retaining Spring Until It Can Be Pressed Out Of Hole Push retaining spring toward the direction of - arrow A - until the spring can be removed from the hole in the caliper. Pull spring out of the caliper in the direction of - arrow B -.

52 Fig. 60: Turning Retaining Spring Until It Can Be Removed From Upper Hole Rotate the retaining spring in the direction of the - arrow - until it can be removed from upper hole. Fig. 61: Identifying Brake Pad Wear Indicator Connector, Dust Cap & Bracket Disconnect the electrical connector for brake pad wear indicator. Remove the clip and remove brake pad wear indicator wire. Remove dust cap and then wire for the brake pad wear indicator at brake caliper. Connect bleeder hose of bleeder bottle to bleeder valve of brake caliper and then open bleeder valve. Insert Brake Pedal Actuator VAG 1869/2. Close bleeder valve and remove bleeder bottle. Disconnect the brake hose.

53 Fig. 62: Identifying Covers Remove covers - arrows -. Fig. 63: Removing Both Guide Pins From Brake Caliper Remove both guide pins - arrows - from the brake caliper. Remove the brake caliper from brake carrier. Remove brake pads from brake caliper. Installing Piston is pressed back. Outer brake pad installed on brake carrier. Insert inner brake pad with retaining spring in brake caliper (piston). NOTE: The inner brake pads (piston side) have a predetermined running direction and are marked for this purpose.

54 Fig. 64: Identifying Right/Left Brake Pad, Piston Side & Position Directional brake pads 1 - Right brake pad, piston side 2 - Left brake pad, piston side When installed, arrow - A - on the backing plate of brake pad must face downward. When installing brake caliper, make sure that brake pad is not affixed to brake caliper before the correct installation position has been reached. Do not damage the adhesion surface. Tighten brake caliper to brake carrier using both guide pins. Install both protective caps. Install the brake caliper hose. Remove Brake Pedal Actuator VAG 1869/2.

55 Fig. 65: Inserting Retaining Spring In Upper Hole Insert retaining spring in upper hole - arrow - and turn in the direction of - arrow -. Attach retaining spring to the lower brake carrier. Fig. 66: Pushing Retaining Spring In First And Then Into Hole Of Brake Caliper At Same Time Push the retaining spring in direction of - arrow A - first and then into hole of brake caliper at the same time direction of - arrow B -. Bleed brake system --> Bleeding braking system. Install wheels. Tightening torque specification for wheel bolts --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT NOTE: Before moving vehicle, depress brake pedal several times firmly to properly seat brake pads in their normal operating position. Check brake fluid level. Tightening torques:

56 Brake caliper pins Brake line to brake caliper 30 Nm 14 Nm Front brakes, servicing, Brembo 17" brake caliper (1LC) Installation date: through kw 32/05 NOTE: 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. Use Brake Charger/bleeder Unit VAS 5234 or Extraction Device Upgrade Kit VAG 1869/4 to extract brake fluid from brake fluid reservoir. Before removing brake caliper or disconnecting brake hose, brake pedal actuator Brake Pedal Actuator VAG 1869/2 must be inserted (this dissipates pressure).

57 Fig. 67: Front Brakes, Servicing, Brembo 17" Brake Caliper (1LC) Remove/Install Components 1 - Brake disc Internally ventilated brake disc: diameter 330 mm Brake disc thickness: 32 mm Wear limit: 30 mm Must always be replaced together on both sides of axle Left differs to right 2 - Installed bolt, 15 Nm Brake disc to wheel hub

58 3 - Brake caliper Do not disconnect brake line when replacing brake disc Removing and installing --> Brake caliper, removing and installing Servicing --> Brembo 17" and 18" brake caliper, servicing 4 - Bolt, 270 Nm Always replace after removal 5 - Brake line, 14 Nm Do not remove brake line when replacing brake disc 6 - Spring clamp 7 - Bracket Bolt to wheel bearing housing 8 - Bolt, 9 Nm 9 - Brake hose Make sure that lugs are properly seated in grooves in bracket Bolt, 30 Nm 11 - Tension strut 12 - Retaining spring 13 - Brake pads Thickness 11 mm without backing plate Wear limit: 2 mm without backing plate With wear indicator When wear limit is reached (limit: approx. 4 mm), the warning lamp lights up in instrument cluster Checking thickness --> 01 - MAINTENANCE Must always be replaced together on both sides of axle Removing and installing --> Brake pads, removing and installing 14 - Wire for brake pad wear indicator

59 Brake pads, removing and installing Special tools, testers and auxiliary items required Fig. 68: Torque Wrench V.A.G 1331 Torque Wrench 5-50nm VAG 1331 Fig. 69: Piston Resetting Tool T10145 Piston Resetting Tool T10145 Removing When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven! Remove wheels.

60 Fig. 72: Identifying Retaining Spring & Tension Strut 2006 Volkswagen Touareg Fig. 70: Identifying Brake Pad Wear Indicator Electrical Connector & Dust Cap Disconnect the electrical connector for brake pad wear indicator. Remove dust cap and remove brake pad wear indicator wire. Fig. 71: Removing/Tightening Bolt Remove bolt.

61 Push retaining spring down - arrow - and then remove tension strut at the same time. Fig. 73: Identifying Brake Pad Wear Indicator & Retaining Spring Remove the wire for brake pad wear indicator - arrows - from the brake caliper housing and out of retaining spring Remove retaining spring. Before pressing brake pads back, draw off brake fluid from reservoir using a bleeder bottle. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage. Fig. 74: Identifying Brake Pads, Brake Caliper & Brake Pad Wear Indicator Wire Press brake pads off brake disc and remove from brake caliper. If brake pads are to be replaced, carefully remove contact sensor with brake pad wear indicator wire from brake pads and check for damage. Reuse undamaged contact sensors and wires.

62 Cleaning: CAUTION: Do not use compressed air to clean brake dust, the dust produced is harmful to health! Clean brake caliper. Use only appropriate solvents for cleaning brake caliper. Installing Before pressing pistons into cylinder using piston resetting tool, brake fluid must be extracted from brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage. Press pistons back. Carefully install brake pad wear indicator wire contact sensor in new brake pads. Fig. 75: Identifying Brake Pads, Brake Caliper & Brake Pad Wear Indicator Wire Insert brake pads into brake caliper.

63 Fig. 76: Identifying Brake Pad Wear Indicator & Retaining Spring Install retaining spring Install the wire for the brake pad wear indicator below tab of retaining spring and in brake caliper housing - arrows -. Fig. 77: Identifying Retaining Spring & Tension Strut Push retaining spring down - arrow - and push tension strut in until stop. Make sure side flat surfaces of tension strut are properly seated in brake caliper housing in order to prevent tension strut from twisting. Fig. 78: Removing/Tightening Bolt Tighten bolt.

64 Fig. 79: Identifying Brake Pad Wear Indicator Electrical Connector & Dust Cap Connect electrical connector for the brake pad wear indicator, and install in bracket on wheel bearing housing. Secure brake pad wear indicator wire with dust cap to bleeder valve. Install wheels. Tightening torque specification for wheel bolts --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT NOTE: 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. Check brake fluid level after replacing brake pad. Tightening torque Bolt to tension strut 30 Nm Brake caliper, removing and installing Special tools, testers and auxiliary items required

65 Fig. 80: Torque Wrench V.A.G 1410 Torque Wrench VAG 1410 Fig. 81: Torque Wrench V.A.G 1576 Torque Wrench VAG 1576 Fig. 82: Brake Pedal Depressor V.A.G 1869/2 Brake Pedal Actuator VAG 1869/2 Removing Work procedure applies only for replacing or when performing subsequent service work on brake caliper. Remove wheels. Connect bleeder hose of bleeder bottle to bleeder valve of brake caliper and then open bleeder valve. Insert Brake Pedal Actuator VAG 1869/2.

66 Close bleeder valve and remove bleeder bottle. Remove brake line from brake caliper. Remove bracket from wheel bearing housing. Remove brake pads --> Brake pads, removing and installing. Remove brake caliper. Installing Install brake caliper. Install brake pads --> Brake pads, removing and installing. Install brake line on brake caliper. Install bracket to wheel bearing housing. Remove Brake Pedal Actuator VAG 1869/2. Bleed brake system --> Bleeding braking system. Install wheels. Tightening torque specification for wheel bolts --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT NOTE: Before moving vehicle, depress brake pedal several times firmly to properly seat brake pads in their normal operating position. Check brake fluid level. Tightening torques: Bolt to wheel bearing housing Use new bolts! Brake line to brake caliper Bolt for bracket to wheel bearing housing 270 Nm 14 Nm 9 Nm Front brakes, servicing, Brembo 17" brake caliper (1LE) Installation date: from kw 32/05 NOTE: 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. Use brake charger/bleeder unit Brake Charger/bleeder Unit VAS 5234 or extraction device Extraction Device Upgrade Kit VAG 1869/4 to extract brake fluid from brake fluid reservoir. Before removing brake caliper or disconnecting brake hose, brake pedal

67 actuator Brake Pedal Actuator VAG 1869/2 must be inserted (this dissipates pressure). Fig. 83: Front Brakes, Servicing, Brembo 17" Brake Caliper (1LE) Remove/Install Components 1 - Brake disc Internally ventilated brake disc: 330 mm diameter Brake disc thickness: 32 mm Wear limit: 30 mm Must always be replaced together on both sides of axle Left differs to right

68 2 - Bolt, 15 Nm Brake disc to wheel hub 3 - Brake caliper Do not remove brake line when replacing brake disc Removing and installing --> Brake caliper, removing and installing Servicing --> Brembo 17" and 18" brake caliper, servicing 4 - Bolt, 270 Nm Always replace after removal 5 - Brake line, 14 Nm Do not remove brake line when replacing brake disc 6 - Spring clamp 7 - Bracket Bolt to wheel bearing housing 8 - Bolt, 9 Nm 9 - Brake hose Make sure that lugs are properly seated in grooves in bracket Brake pad retaining pins 11 - Retaining spring 12 - Brake pads Thickness 11 mm without backing plate Wear limit: 2 mm without backing plate With wear indicator When wear limit is reached (limit: approx. 4 mm), the warning lamp lights up in instrument cluster Checking thickness --> 01 - MAINTENANCE Must always be replaced together on both sides of axle Removing and installing --> Brake pads, removing and installing

69 13 - Wire for brake pad wear indicator Brake pads, removing and installing Special tools, testers and auxiliary items required Fig. 84: Piston Resetting Tool T10145 Piston Resetting Tool T10145 Removing When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven! Remove wheels. Fig. 85: Identifying Brake Pad Wear Indicator Electrical Connector & Dust Cap Disconnect the electrical connector for brake pad wear indicator. Remove dust cap and remove brake pad wear indicator wire.

70 Fig. 86: Removing Brake Pad Retaining Pins Remove brake pad retaining pins - arrows -. Fig. 87: Identifying Brake Pad Wear Indicator & Retaining Spring Remove the wire for brake pad wear indicator - arrows - out of brake caliper housing and out of retaining spring Remove retaining spring. Before pressing brake pads back, draw off brake fluid from reservoir using a bleeder bottle. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.

71 Fig. 88: Identifying Brake Pads, Brake Caliper & Brake Pad Wear Indicator Wire Press brake pads off brake disc and remove from brake caliper. If brake pads are to be replaced, carefully remove contact sensor with brake pad wear indicator wire from brake pads and check for damage. Reuse undamaged contact sensors and wires. Cleaning: CAUTION: Do not use compressed air to clean brake dust, the dust produced is harmful to health! Clean brake caliper. Use only appropriate solvents for cleaning brake caliper. Installing Before pressing pistons into cylinder using piston resetting tool, brake fluid must be extracted from brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage. Press pistons back. Carefully install brake pad wear indicator wire contact sensor in new brake pads.

72 Fig. 89: Identifying Brake Pads, Brake Caliper & Brake Pad Wear Indicator Wire Install brake pads into brake caliper. Fig. 90: Identifying Brake Pad Wear Indicator & Retaining Spring Insert retaining spring Install wire for brake pad wear indicator below tab of retaining spring and in brake caliper housing - arrows -. Press retaining spring down and place pad retaining pin in brake caliper.

73 Fig. 91: Driving Pad Retaining Pin Into Brake Caliper As Far As Stop Drive pad retaining pin into brake caliper as far as stop. Fig. 92: Identifying Brake Pad Wear Indicator Electrical Connector & Dust Cap Install electrical connector of brake pad wear indicator into bracket of wheel bearing housing. Secure wire of brake pad wear indicator with dust cap to bleeder valve. Install wheels. Tightening torque specification for wheel bolts --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT NOTE: 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. Check brake fluid level after replacing brake pads. Brake caliper, removing and installing Special tools, testers and auxiliary items required

74 Fig. 93: Torque Wrench V.A.G 1410 Torque Wrench VAG 1410 Fig. 94: Torque Wrench V.A.G 1576 Torque Wrench VAG 1576 Fig. 95: Brake Pedal Depressor V.A.G 1869/2

75 Brake Pedal Actuator VAG 1869/2 Removing Work procedure applies only for replacing or when performing subsequent service work on brake caliper. Remove wheels. Connect bleeder hose of bleeder bottle to bleeder valve of brake caliper and then open bleeder valve. Install Brake Pedal Actuator VAG 1869/2. Close bleeder valve and remove bleeder bottle. Remove brake line from brake caliper. Remove bracket from wheel bearing housing. Remove brake pads --> Brake pads, removing and installing. Remove brake caliper from wheel bearing housing. Installing Install brake caliper onto wheel bearing housing. Install brake pads. Install brake line on brake caliper. Install bracket to wheel bearing housing. Remove Brake Pedal Actuator VAG 1869/2. Bleed brake system --> Bleeding braking system. Install wheels. Tightening torque specification for wheel bolts --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT NOTE: Before moving vehicle, depress brake pedal several times firmly to properly seat brake pads in their normal operating position. Check brake fluid level. Tightening torques: Bolt to wheel bearing housing Use new bolts! Brake line to brake caliper Bolt for bracket to wheel bearing housing 270 Nm 14 Nm 9 Nm Front brakes, servicing, Brembo 18" brake caliper

76 NOTE: 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. Use brake charger/bleeder unit Brake Charger/bleeder Unit VAS 5234 or extraction device Extraction Device Upgrade Kit VAG 1869/4 to extract brake fluid from brake fluid reservoir. Before removing brake caliper or disconnecting brake hose, brake pedal actuator Brake Pedal Actuator VAG 1869/2 must be inserted (this dissipates pressure). Fig. 96: Front Brakes, Servicing, Brembo 18" Brake Caliper Remove/Install Components 1 - Brake disc

77 Internally ventilated brake disc: 350 mm diameter Brake disc thickness: 34 mm Wear limit: 32 mm Always replace together on both sides of axle Left to right are different 2 - Bolt, 15 Nm Brake disc to wheel hub 3 - Brake caliper Do not remove the brake line when replacing brake disc Removing and installing --> Brake caliper, removing and installing Servicing --> Brembo 17" and 18" brake caliper, servicing 4 - Bolt, 270 Nm Always replace after removal 5 - Brake line, 14 Nm Do not remove brake line when replacing brake disc 6 - Spring clamp 7 - Bracket Bolt to wheel bearing housing 8 - Bolt, 9 Nm 9 - Brake hose Make sure that lugs are properly seated in grooves in bracket Bolt, 30 Nm 11 - Tension strut 12 - Retaining spring 13 - Brake pads

78 Thickness 11 mm without backing plate Wear limit: 2 mm without backing plate With wear indicator When wear limit is reached (limit: approx. 4 mm), the warning lamp lights up in instrument cluster Checking thickness --> 01 - MAINTENANCE Must always be replaced together on both sides of axle Removing and installing --> Brake pads, removing and installing 14 - Wire for brake pad wear indicator Brake pads, removing and installing Special tools, testers and auxiliary items required Fig. 97: Torque Wrench V.A.G 1331 Torque Wrench 5-50nm VAG 1331 Fig. 98: Piston Resetting Tool T10145

79 Piston Resetting Tool T10145 Removing When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven! Remove wheels. Fig. 99: Identifying Brake Pad Wear Indicator Electrical Connector & Dust Cap Disconnect the electrical connector for brake pad wear indicator. Remove dust cap and remove brake pad wear indicator wire. Fig. 100: Removing/Tightening Bolt Remove bolt.

80 Fig. 101: Identifying Retaining Spring & Tension Strut Press retaining spring down - arrow - and remove tension strut at the same time. Fig. 102: Identifying Brake Pad Wear Indicator & Retaining Spring Pull wire for brake pad wear indicator - arrows - out of brake caliper housing and out of retaining spring Remove retaining spring. Before pressing brake pads back, draw off brake fluid from reservoir using a bleeder bottle. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.

81 Fig. 103: Identifying Brake Pads, Brake Caliper & Brake Pad Wear Indicator Wire Press brake pads off brake disc and remove from brake caliper. If brake pads are to be replaced, carefully remove contact sensor with brake pad wear indicator wire from brake pads and check for damage. Reuse undamaged contact sensors and wires. Cleaning: CAUTION: Do not use compressed air to clean brake dust, the dust produced is harmful to health! Clean brake caliper. Use only appropriate solvents for cleaning brake caliper. Installing Before pressing pistons into cylinder using piston resetting tool, brake fluid must be extracted from brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage. Press pistons back. Carefully install brake pad wear indicator wire contact sensor in new brake pads.

82 Fig. 104: Identifying Brake Pads, Brake Caliper & Brake Pad Wear Indicator Wire Install brake pads into brake caliper. Fig. 105: Identifying Brake Pad Wear Indicator & Retaining Spring Insert retaining spring Install wire for brake pad wear indicator below tab of retaining spring and in brake caliper housing - arrows -.

83 Fig. 106: Identifying Retaining Spring & Tension Strut Press retaining spring down - arrow - and install tension strut in until stop. Make sure side flat surfaces of tension strut are properly seated in brake caliper housing in order to prevent tension strut from twisting. Fig. 107: Removing/Tightening Bolt Tighten bolt. Fig. 108: Identifying Brake Pad Wear Indicator Electrical Connector & Dust Cap Connect electrical connector of brake pad wear indicator in bracket of wheel bearing housing. Secure wire of brake pad wear indicator with dust cap to bleeder valve. Install wheels. Tightening torque specification for wheel bolts --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT NOTE: After replacing brake pads, depress brake pedal firmly several times with

84 vehicle stationary so that the brake pads are properly seated in their normal operating position. Check brake fluid level after replacing brake pads. Tightening torque Bolt to tension strut 30 Nm Brake caliper, removing and installing Special tools, testers and auxiliary items required Fig. 109: Torque Wrench V.A.G 1410 Torque Wrench VAG 1410 Fig. 110: Torque Wrench V.A.G 1576 Torque Wrench VAG 1576

85 Fig. 111: Brake Pedal Depressor V.A.G 1869/2 Brake Pedal Actuator VAG 1869/2 Removing Work procedure applies only for replacing or when performing subsequent service work on brake caliper. Remove wheels. Connect bleeder hose of bleeder bottle to bleeder valve of brake caliper and then open bleeder valve. Install Brake Pedal Actuator VAG 1869/2. Close bleeder valve and remove bleeder bottle. Remove brake line from brake caliper. Remove bracket from wheel bearing housing. Remove brake pads --> Brake pads, removing and installing. Remove brake caliper from wheel bearing housing. Installing Install brake caliper onto wheel bearing housing. Install brake pads --> Brake pads, removing and installing. Install brake line on brake caliper. Install bracket to wheel bearing housing. Remove Brake Pedal Actuator VAG 1869/2. Bleed brake system --> Bleeding braking system. Install wheels. Tightening torque specification for wheel bolts --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT

86 NOTE: Before moving vehicle, depress brake pedal several times firmly to properly seat brake pads in their normal operating position. Check brake fluid level. Tightening torques: Bolt to wheel bearing housing Use new bolts! Brake line to brake caliper Bolt for bracket to wheel bearing housing 270 Nm 14 Nm 9 Nm REAR BRAKE, SERVICING Rear brakes, servicing, brake caliper FN 44 NOTE: 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. Use brake charger/bleeder unit Brake Charger/bleeder Unit VAS 5234 or extraction device Extraction Device Upgrade Kit VAG 1869/4 to extract brake fluid from brake fluid reservoir. Before removing brake caliper or disconnecting brake hose, brake pedal actuator Brake Pedal Actuator VAG 1869/2 must be inserted (this dissipates pressure).

87 Fig. 112: Rear Brakes, Servicing, Brake Caliper FN 44 Remove/Install Components 1 - Brake disc/brake drum Ventilated brake disc: 314 mm diameter Brake disc thickness: 22 mm Wear limit: 18 mm Brake drum: 185 mm diameter Wear limit: 186 mm Must always be replaced together on both sides of axle To remove, first remove brake caliper and brake carrier, do not remove brake line 2 - Bolt, 20 Nm

88 Brake disc to wheel hub 3 - Brake carrier Bolt to wheel bearing housing 4 - Bolt, 200 Nm 5 - Brake pads Thickness 13 mm without backing plate Wear limit: 2 mm without backing plate With wear indicator When wear limit is reached (limit: approx. 4 mm), the warning lamp lights up in instrument cluster Checking thickness --> 01 - MAINTENANCE Must always be replaced together on both sides of axle Removing and installing --> Brake pads, removing and installing 6 - Retaining spring 7 - Brake caliper Do not remove brake hose when replacing brake pads or brake discs Removing and installing --> Brake caliper, removing and installing Servicing --> Brake caliper FN 44, servicing 8 - Bracket for brake pad wear indicator wire 9 - Bolt, 10 Nm 10 - Guide pins, 30 Nm (18 ft lb) 11 - Concealment cap 12 - Bolt, 8 Nm 13 - Bracket 14 - Brake hose with connection and banjo fitting, 38 Nm Do not remove when replacing brake pads or brake discs 15 - Spring dowel sleeve

89 16 - Compression spring 17 - Pull spring Component location: At adjustment nut Larger number of spring coil Can be easily bent by hand 18 - Spring Component location: At spreader Smaller number of spring coil Cannot be easily bent by hand 19 - Brake shoe Removing and installing --> Brake shoes, removing and installing Minimum pad thickness 1 mm Checking thickness 20 - Spreader 21 - Adjustment nut Adjust parking brake --> Parking brake, adjusting 22 - Brake carrier 23 - Rear brake cable Brake pads, removing and installing Special tools, testers and auxiliary items required

90 Fig. 113: Torque Wrench V.A.G 1331 Torque Wrench 5-50nm VAG 1331 Fig. 114: Piston Resetting Tool T10145 Piston Resetting Tool T10145 Removing When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven! Remove wheels. Fig. 115: Pushing Retaining Spring Until It Can Be Pressed Out Of Hole Push retaining spring toward direction of - arrow A - until it can be pulled out of hole in the direction of - arrow B -.

91 Fig. 116: Turning Retaining Spring Until It Can Be Removed From Upper Hole Rotate retaining spring in the direction of the - arrow - until it can be removed from upper hole. Fig. 117: Identifying Brake Pad Wear Indicator Connector, Brake Caliper Bracket, Rake Pad Wear Indicator And Wheel Speed Sensor Wire & Connector Separate the connector for brake pad wear indicator. Release the wire for brake pad wear indicator from bracket at brake caliper. Remove bottom of connector of brake pad wear indicator and wheel speed sensor wire from brake caliper bracket.

92 Fig. 118: Identifying Covers Remove covers - arrows -. Fig. 119: Removing Both Caliper Guide Pins From Brake Caliper Remove both caliper guide pins - arrows - from brake caliper. Remove brake caliper and secure with wire so that the weight of the brake caliper does not burden or damage the brake hose. Remove brake pads. Cleaning: CAUTION: Do not use compressed air to clean brake dust, the dust produced is harmful to health! Thoroughly clean contact surfaces for brake pads at brake carrier, remove corrosion. Clean brake caliper. Use only appropriate solvents for cleaning brake caliper.

93 Installing Before pressing pistons into cylinder using piston resetting tool, brake fluid must be extracted from brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage. Fig. 120: Pressing Pistons Back Using Piston Resetting Tool T10145 Press pistons back using Piston Resetting Tool T NOTE: The inner brake pads (piston side) have a predetermined running direction and are marked for this purpose. Fig. 121: Identifying Directional Brake Pads Position

94 Directional brake pads When installed, arrow - A - on the backing plate of brake pad must face downward. Fig. 122: Installing Brake Pad And Retaining Springs Into Caliper Piston Install brake pad and retaining springs into caliper piston - arrows -. Install outer brake pad on brake carrier. Fig. 123: Removing Both Caliper Guide Pins From Brake Caliper Tighten both brake caliper pins to brake carrier - arrows -. Install both protective caps.

95 Fig. 124: Identifying Brake Pad Wear Indicator Connector, Brake Caliper Bracket, Rake Pad Wear Indicator And Wheel Speed Sensor Wire & Connector Install wheel speed sensor wire into bracket at brake caliper. Secure electrical connectors and of brake pad wear indicator to the brake caliper bracket. Secure wire of brake pad wear indicator in bracket at brake caliper. Fig. 125: Inserting Retaining Spring In Upper Hole Install retaining spring in upper hole - arrow - and rotate in the direction of - arrow -. Attach retaining spring at lower brake carrier.

96 Fig. 126: Pushing Retaining Spring In First And Then Into Hole Of Brake Caliper At Same Time Push retaining spring in direction of - arrow A - first and then into hole of brake caliper at the same time direction of - arrow B -. Install wheels. Torque specification for wheel bolts --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT NOTE: 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. Check brake fluid level after replacing brake pads. Tightening torque Brake caliper to brake carrier 30 Nm Brake caliper, removing and installing Special tools, testers and auxiliary items required Fig. 127: Torque Wrench V.A.G 1331

97 Torque Wrench 5-50nm VAG 1331 Fig. 128: Brake Pedal Depressor V.A.G 1869/2 Brake Pedal Actuator VAG 1869/2 Removing Work procedure applies only for replacing or when performing subsequent service work on brake caliper. Remove wheels. Fig. 129: Pushing Retaining Spring Until It Can Be Pressed Out Of Hole Push retaining spring toward direction of - arrow A - until it can be removed from the hole in the direction of - direction of arrow B -.

98 Fig. 130: Turning Retaining Spring Until It Can Be Removed From Upper Hole Rotate the retaining spring in the direction of the - arrow - until it can be removed from upper hole. Fig. 131: Identifying Brake Pad Wear Indicator Connector, Brake Caliper Bracket, Rake Pad Wear Indicator And Wheel Speed Sensor Wire & Connector Disconnect the electrical connector from the brake pad wear indicator. Remove the wire for brake pad wear indicator from the bracket at brake caliper. Remove bottom of connector of brake pad wear indicator and wheel speed sensor wire from brake caliper bracket. Connect bleeder hose of bleeder bottle to bleeder valve of brake caliper and then open bleeder valve. Insert Brake Pedal Actuator VAG 1869/2. Close bleeder valve and remove bleeder bottle. Remove brake line.

99 Fig. 132: Identifying Covers Remove covers - arrows -. Fig. 133: Removing Both Caliper Guide Pins From Brake Caliper Remove both guide pins - arrows - from the brake caliper. Remove the brake caliper from brake carrier. Remove the brake pads from brake caliper. Installing Piston is pressed back. Outer brake pad sits on brake carrier. Install inner brake pad, with retaining spring, to the brake caliper (piston). NOTE: The inner brake pads (piston side) have a predetermined running direction and are marked for this purpose.

100 Fig. 134: Identifying Directional Brake Pads Position Directional brake pads When installed, arrow - A - on the backing plate of brake pad must face downward. Fig. 135: Removing Both Caliper Guide Pins From Brake Caliper Secure brake caliper to brake carrier using both guide pins - arrows -. Install both protective caps. Install brake hose on brake caliper. Remove Brake Pedal Actuator VAG 1869/2.

101 Fig. 136: Identifying Brake Pad Wear Indicator Connector, Brake Caliper Bracket, Rake Pad Wear Indicator And Wheel Speed Sensor Wire & Connector Install wheel speed sensor wire into bracket at brake caliper. Install electrical connectors and for the brake pad wear indicator into the brake caliper bracket. Secure brake pad wear indicator wire to the bracket at brake caliper. Fig. 137: Inserting Retaining Spring In Upper Hole Insert retaining spring in upper hole - arrow - and rotate in the direction of - arrow -. Attach retaining spring to lower brake carrier.

102 Fig. 138: Pushing Retaining Spring In First And Then Into Hole Of Brake Caliper At Same Time Push retaining spring in the direction of - arrow A - first and then into hole of brake caliper at the same time direction of - arrow B -. Bleed brake system --> Bleeding braking system. Install wheels. Tightening torque specification for wheel bolts --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT NOTE: Before moving vehicle, depress brake pedal several times firmly to properly seat brake pads in their normal operating position. Check brake fluid level. Tightening torques: Caliper guide pin to brake carrier Brake hose banjo fitting to brake caliper 30 Nm 38 Nm Brake shoes, removing and installing Special tools, testers and auxiliary items required

103 Fig. 139: Hook 3438 Hook 3438 Removing Remove wheels. Remove brake pads --> Brake pads, removing and installing Remove brake caliper carrier. Rotate brake disc until adjustment nut of parking brake can be seen through a wheel bolt hole. Back off parking brake adjustment: Fig. 140: Turning Adjustment Nut Against Resistance From Pull-Spring Turn adjustment nut - A - against resistance from pull-spring - B -. Remove brake disc/brake drum. Remove pull springs. Remove spring dowel sleeves with compression springs and remove brake shoes. Installing Installation is performed in the reverse order of removal. Adjust parking brake --> Parking brake, adjusting. Rear brakes, servicing, brake caliper Brembo (1KF) Installation date: through kw 22/06 NOTE: After replacing brake pads, depress brake pedal firmly several times with

104 vehicle stationary so that the brake pads are properly seated in their normal operating position. Use brake charger/bleeder unit Brake Charger/bleeder Unit VAS 5234 or extraction device Extraction Device Upgrade Kit VAG 1869/4 to extract brake fluid from brake fluid reservoir. Before removing brake caliper or disconnecting brake hose, brake pedal actuator Brake Pedal Actuator VAG 1869/2 must be inserted (this dissipates pressure). Fig. 141: Rear Brakes, Servicing, Brake Caliper Brembo (1KF) Remove/Install Components 1 - Brake disc/brake drum Internally ventilated brake disc: 330 mm diameter

105 Brake disc thickness: 28 mm Wear limit: 26 mm Brake drum: 210 mm diameter Wear limit: 211 mm Must always be replaced together on both sides of axle To remove, first remove brake caliper, do not remove brake line 2 - Bolt, 14 Nm Brake disc to wheel hub 3 - Bolt, 14 Nm For adjustment nut of parking brake 4 - Brake caliper Do not remove brake line when replacing brake disc Removing and installing --> Brake caliper, removing and installing Servicing --> Brembo 17" brake caliper, servicing 5 - Bolt, 150 Nm + 90 (1/4-turn) Always replace after removal 6 - Bolt 7 - Protective plate 8 - Brake pads Thickness 11 mm without backing plate Wear limit: 2 mm without backing plate With wear indicator When wear limit is reached (limit: approx. 4 mm), the warning lamp lights up in instrument cluster Checking thickness: --> 01 - MAINTENANCE Must always be replaced as a set, both sides of the axle Removing and installing --> Brake pads, removing and installing 9 - Wire for brake pad wear indicator

106 10 - Cotter pin 11 - Pad retaining pin 12 - Retaining spring 13 - Bracket Bolt to brake caliper housing 14 - Bolt, 8 Nm 15 - Spring clamp 16 - Brake line, 14 Nm Do not remove brake line when replacing brake disc 17 - Brake hose Do not remove brake hose when replacing brake disc Make sure that lugs are properly seated in grooves in bracket Spring dowel sleeve 19 - Compression spring 20 - Pull spring Component location: At adjustment nut Larger number of spring coil Can be easily bent by hand 21 - Pull-spring Component location: At spreader Smaller number of spring coil Cannot be easily bent by hand 22 - Spreader 23 - Adjustment nut Adjust parking brake --> Parking brake, adjusting

107 24 - Brake shoe Removing and installing --> Brake shoes, removing and installing Minimum pad thickness 1 mm Checking thickness 25 - Brake carrier 26 - Rear brake cable Brake pads, removing and installing Special tools, testers and auxiliary items required Fig. 142: Piston Resetting Tool T10145 Piston Resetting Tool T10145 Removing NOTE: When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven! Remove wheels.

108 Fig. 143: Disconnecting/Connecting Connector For Brake Pad Wear Indicator Disconnect the connector for brake pad wear indicator. Fig. 144: Removing/Installing Cotter Pin From Pad Retaining Pin Remove the cotter pin - arrow - from the pad retaining pin. Fig. 145: Pushing Retaining Spring Down And Removing Pad Retaining Pin

109 Push retaining spring down - arrow - and remove pad retaining pin at the same time. Fig. 146: Removing/Installing Brake Pad Wear Indicator Wire From Brake Caliper Housing And Retaining Spring Remove brake pad wear indicator wire from the brake caliper housing and retaining spring Remove retaining spring. Before pressing brake pads back, draw off brake fluid from reservoir using a bleeder bottle. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage. Fig. 147: Identifying Brake Pads, Brake Caliper & Brake Pad Wear Indicator Wire Press brake pads off brake disc and remove from brake caliper. If brake pads are to be replaced, carefully remove contact sensor with brake pad wear indicator wire from brake pads and check for damage. Reuse undamaged contact sensors and wires. Cleaning:

110 CAUTION: Do not use compressed air to clean brake dust, the dust produced is harmful to health! Clean brake caliper. Use only appropriate solvents for cleaning brake caliper. Installing Before pressing piston into cylinder using piston resetting tool, brake fluid must be extracted from brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage. Press pistons back. Carefully install brake pad wear indicator sensor into the new brake pads. Fig. 148: Identifying Brake Pads, Brake Caliper & Brake Pad Wear Indicator Wire Insert brake pads into brake caliper housing. Fig. 149: Removing/Installing Brake Pad Wear Indicator Wire From Brake Caliper Housing And Retaining Spring

111 Insert retaining spring Install wire for brake pad wear indicator below tab of retaining spring and in brake caliper housing - arrows -. Fig. 150: Pushing Retaining Spring Down And Removing Pad Retaining Pin Push retaining spring down - arrow - and install pad retaining pin in until stop. Fig. 151: Removing/Installing Cotter Pin From Pad Retaining Pin Secure pad retaining pin using a cotter pin - arrow -.

112 Fig. 152: Disconnecting/Connecting Connector For Brake Pad Wear Indicator Secure brake pad wear indicator electrical connector to the brake caliper bracket. Install wheels --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT NOTE: 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. Check brake fluid level after replacing brake pad. Brake caliper, removing and installing Special tools, testers and auxiliary items required Fig. 153: Torque Wrench V.A.G Torque Wrench mm VAG 1332

113 Fig. 154: Socket XZN 16 T10198 Socket XZN 16 T10198 Fig. 155: Brake Pedal Depressor V.A.G 1869/2 Brake Pedal Actuator VAG 1869/2 Removing Work procedure applies only when replacing or when performing subsequent service work on brake caliper. Remove wheels. Connect bleeder hose of bleeder bottle to bleeder valve of brake caliper and then open bleeder valve. Insert Brake Pedal Actuator VAG 1869/2. Close bleeder valve and remove bleeder bottle. Remove brake line from brake caliper. Remove brake pads --> Brake pads, removing and installing

114 Remove brake caliper. Installing Install brake caliper onto wheel bearing housing. Install brake pads --> Brake pads, removing and installing. Install brake line to brake caliper. Secure wheel speed sensor wire to bracket at brake caliper. Remove Brake Pedal Actuator VAG 1869/2. Bleed brake system --> Bleeding braking system. Install wheels. Tightening torque specification for wheel bolts --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT NOTE: Before moving vehicle, depress brake pedal several times firmly to properly seat brake pads in their normal operating position. Check brake fluid level. Tightening torques: Brake caliper bolt to wheel bearing housing Use new bolts! Brake line to brake caliper 150 Nm and 90 (1/8 turn) 14 Nm Brake shoes, removing and installing Special tools, testers and auxiliary items required Fig. 156: Hook 3438

115 Set back parking brake: 2006 Volkswagen Touareg Hook 3438 Fig. 157: Socket XZN 16 T10198 Socket XZN 16 T10198 Removing Remove wheels. Remove brake pads --> Brake pads, removing and installing Remove wheel speed sensor wire from brake caliper bracket. Remove brake caliper mounting bolts. Remove brake caliper housing and secure with wire so that the weight of the brake caliper does not burden or damage the brake hose. Fig. 158: Removing Bolt For Adjustment Nut Of Parking Brake Remove bolt - arrow - for adjustment nut of parking brake.

116 Fig. 159: Turning Adjustment Nut Against Resistance From Pull-Spring Turn adjustment nut - A - against resistance from pull-spring - B -. Remove brake disc/brake drum. Remove pull-springs. Remove spring dowel sleeves with compression springs and remove brake shoes. Installing Installation is performed in the reverse order of removal. Adjust parking brake --> Parking brake, adjusting. Rear brakes, servicing, brake caliper Brembo (1KQ) Installation date: from KW 22/06 NOTE: 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. Use brake charger/bleeder unit Brake Charger/bleeder Unit VAS 5234 or extraction device Extraction Device Upgrade Kit VAG 1869/4 to extract brake fluid from brake fluid reservoir. Before removing brake caliper or disconnecting brake hose, brake pedal actuator Brake Pedal Actuator VAG 1869/2 must be inserted (this dissipates pressure).

117 Fig. 160: Rear Brakes, Servicing, Brake Caliper Brembo (1KQ) Remove/Install Components 1 - Brake disc/brake drum Internally ventilated brake disc: 330 mm diameter Brake disc thickness: 28 mm Wear limit: 26 mm Brake drum: 210 mm diameter Wear limit: 211 mm Must always be replaced as a set, both sides of axle To remove, first remove brake caliper, do not remove brake line 2 - Bolt, 14 Nm

118 Brake disc to wheel hub 3 - Bolt, 14 Nm For adjustment nut of parking brake 4 - Brake caliper Do not remove brake line when replacing brake disc Removing and installing --> Brake caliper, removing and installing Servicing --> Brembo 17" brake caliper, servicing 5 - Bolt, 150 Nm + 90 (1/4-turn) Always replace after removal 6 - Brake pads Thickness 11 mm without backing plate Wear limit: 2 mm without backing plate With wear indicator When wear limit is reached (limit: approx. 4 mm), the warning lamp lights up in instrument cluster Checking thickness: --> 01 - MAINTENANCE Must always be replaced together on both sides of axle Removing and installing --> Brake pads, removing and installing 7 - Wire for brake pad wear indicator 8 - Pad retaining pin 9 - Retaining spring 10 - Bracket Fasten to brake caliper housing 11 - Bolt, 8 Nm 12 - Spring clamp 13 - Brake line, 14 Nm Do not remove brake line when replacing brake disc

119 14 - Brake hose Do not remove brake hose when replacing brake disc Make sure that lugs are properly seated in grooves in bracket Spring dowel sleeve 16 - Compression spring 17 - Pull-spring Component location: At adjustment nut Larger number of spring coil Can be easily bent by hand 18 - Pull-spring Component location: At spreader Smaller number of spring coil Cannot be easily bent by hand 19 - Spreader 20 - Adjustment nut Adjust parking brake --> Parking brake, adjusting 21 - Brake shoe Removing and installing --> Brake shoes, removing and installing Minimum pad thickness 1 mm Checking thickness 22 - Brake carrier 23 - Rear brake cable Brake pads, removing and installing Special tools, testers and auxiliary items required

120 Fig. 161: Piston Resetting Tool T10145 Piston Resetting Tool T10145 Removing NOTE: When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven! Remove wheels. Fig. 162: Disconnecting/Connecting Connector For Brake Pad Wear Indicator Disconnect the electrical connector for brake pad wear indicator.

121 Fig. 163: Removing Brake Pad Retaining Pins Remove brake pad retaining pins - arrows -. Fig. 164: Removing/Installing Brake Pad Wear Indicator Wire From Brake Caliper Housing And Retaining Spring Remove brake pad wear indicator wire from brake caliper housing and retaining spring Remove retaining spring. Before pressing brake pads back, draw off brake fluid from reservoir using a bleeder bottle. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.

122 Fig. 165: Identifying Brake Pads, Brake Caliper & Brake Pad Wear Indicator Wire Press brake pads off brake disc and remove from brake caliper. If brake pads are to be replaced, carefully remove contact sensor with brake pad wear indicator wire from brake pads and check for damage. Reuse undamaged contact sensors and wires. Cleaning: CAUTION: Do not use compressed air to clean brake dust, the dust produced is harmful to health! Clean brake caliper. Use only appropriate solvents for cleaning brake caliper. Installing Before pressing piston into cylinder using piston resetting tool, brake fluid must be extracted from brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage. Press pistons back. Carefully install brake pad wear indicator contact sensor in new brake pads.

123 Fig. 166: Identifying Brake Pads, Brake Caliper & Brake Pad Wear Indicator Wire Install brake pads into brake caliper housing. Fig. 167: Removing/Installing Brake Pad Wear Indicator Wire From Brake Caliper Housing And Retaining Spring Install retaining spring Install wire for brake pad wear indicator below tab of retaining spring - arrows - and in brake caliper housing. Press retaining spring down and install pad retaining pin in brake caliper.

124 Fig. 168: Installing Pad Retaining Pin Into Brake Caliper As Far As Stop Install pad retaining pin into brake caliper as far as stop. Fig. 169: Disconnecting/Connecting Connector For Brake Pad Wear Indicator Secure connector of brake pad wear indicator into bracket on the brake caliper housing. Install wheels --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT NOTE: 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. Check brake fluid level after replacing brake pad. Brake caliper, removing and installing Special tools, testers and auxiliary items required

125 Fig. 170: Torque Wrench V.A.G Torque Wrench mm VAG 1332 Fig. 171: Socket XZN 16 T10198 Socket XZN 16 T10198 Fig. 172: Brake Pedal Depressor V.A.G 1869/2

126 Brake Pedal Actuator VAG 1869/2 Removing Work procedure applies only for replacing or when performing subsequent service work on brake caliper. Remove wheels. Connect bleeder hose of bleeder bottle to bleeder valve of brake caliper and then open bleeder valve. Install Brake Pedal Actuator VAG 1869/2. Close bleeder valve and remove bleeder bottle. Remove brake line from brake caliper. Remove brake pads --> Brake pads, removing and installing. Remove wheel speed sensor wire from the brake caliper bracket. Remove brake caliper. Installing Install brake caliper onto wheel bearing housing. Install brake pads --> Brake pads, removing and installing. Install brake line onto brake caliper. Secure wheel speed sensor wire to the bracket at brake caliper. Remove Brake Pedal Actuator VAG 1869/2. Bleed brake system --> Bleeding braking system. Install wheels. Tightening torque specification for wheel bolts --> 44 - WHEELS, TIRES, WHEEL ALIGNMENT NOTE: Before moving vehicle, depress brake pedal several times firmly to properly seat brake pads in their normal operating position. Check brake fluid level. Tightening torques: Brake caliper bolt to wheel bearing housing Use new bolts! Brake line to brake caliper 150 Nm and 90 (1/8 turn) 14 Nm Brake shoes, removing and installing

127 Fig. 173: Hook 3438 Hook 3438 Fig. 174: Socket XZN 16 T10198 Socket XZN 16 T10198 Removing Remove wheels. Remove brake pads Remove wheel speed sensor wire out of bracket at brake caliper. Remove brake caliper mounting bolts. Remove brake caliper housing and secure with wire so that the weight of the brake caliper does not burden or damage the brake hose.

128 Fig. 175: Removing Bolt For Adjustment Nut Of Parking Brake Remove bolt - arrow - for adjustment nut of parking brake. Backing off parking brake: Fig. 176: Turning Adjustment Nut Against Resistance From Pull-Spring Turn adjustment nut - A - against resistance from pull-spring - B -. Remove brake disc/brake drum. Remove pull-springs. Remove spring dowel sleeves with compression springs and remove brake shoes. Installing Installation is performed in the reverse order of removal. Adjust parking brake --> Parking brake, adjusting. Parking brake, adjusting

129 Adjustment must only be performed at the rear wheels! Adjustment must never be performed parking brake lever or transfer module on center console! Observe correct routing and guiding of parking brake cables! If the brake shoes were replaced, adjust air gap to the 6th tooth. Then run in brake shoes by braking vehicle in a single maneuver from a speed of approximately. 50 km/h. Rear wheels must not lock up when doing so. Parking brake lever in released position. Remove rear wheels. Brake discs must move freely. If necessary, press brake pads slightly back or move rear brake cables slightly to and fro. Fig. 177: Removing Bolt For Adjustment Nut Of Parking Brake Remove bolt - arrow - for adjustment nut of parking brake. Adjusting brake shoes on both wheels: Fig. 178: Turning Adjustment Nut Against Resistance From Pull-Spring

130 Push screwdriver through hole in brake disc and turn adjustment nut - A - against resistance of pull-spring - B - until brake disc can no longer be turned. Then loosen adjustment nut 6 teeth. Brake discs must move freely again. Free play of parking brake lever must be checked again. Install wheels. Checking free play of foot operated parking brake lever: Actuate parking brake pedal 2 teeth/clicks, wheels must rotate freely without brake shoes dragging. Operated parking brake lever 5 to 7 teeth/clicks, wheels must be fixed. If wheels can still be rotated, parking brake must be adjusted. PARKING BRAKE PEDAL - ASSEMBLY OVERVIEW Foot operated parking brake

131 Fig. 179: Foot Operated Parking Brake - Assembly Overview 1 - Release handle 2 - Release cable 3 - Mount 4 - Foot operated parking brake lever Removing and installing --> Foot operated parking brake lever, removing and installing 5 - Bolt, 23 Nm 6 - Bolt, 23 Nm 7 - Front brake cable Removing and installing --> Front brake cable, removing and installing 8 - Bolt, 2 Nm 9 - Contact switch for parking brake Transfer module

132 Fig. 180: Transfer Module - Assembly Overview 1 - Transfer module 2 - Washer 3 - Bumper 4 - Cable anchor bracket 5 - Bolt 6 - Cable anchor 7 - Compensator bracket

133 8 - Nut 9 - Bolt, 23 Nm 10 - Clip 11 - Front brake cable Removing and installing --> Front brake cable, removing and installing 12 - Rear brake cables Removing and installing --> Rear brake cables, removing and installing Rear brake cable Fig. 181: Rear Brake Cable - Assembly Overview 1 - Rear brake cable 2 - Sealing ring 3 - Sealing ring 4 - Sleeve 5 - Securing ring Foot operated parking brake lever, removing and installing Removing Remove trim on drivers side --> 70 - INTERIOR TRIM. Disconnect connector from contact switch for parking brake.

134 Remove left fuse holder and lay aside as far as possible together with wiring harness --> 97 - WIRING. Fig. 182: Identifying Spring Plate Of Release Spring & Spring For Cable Compensation First press spring plate of release spring arrow - A - downward in order to compress the spring for cable compensation arrow - B -. Hold spring - arrow B - compressed. Fig. 183: Identifying Foot Operated Parking Brake Lever Secure compressed spring by e.g. sliding a drill through holes of the foot operated parking brake lever - arrow - and through the linked cable mounting.

135 Fig. 184: Identifying Brake Cable, Cable Mounting & Cable Sleeve Disconnect the brake cable - A - from cable mounting of foot operated parking brake lever. Remove cable sleeve from mount. Remove both mounting bolts of foot operated parking brake lever. Remove foot operated parking brake from mount. Installing Installation is performed in the reverse sequence. Remove transport protection device (drill) from foot operated parking brake lever. There will be an automatic length compensation of the brake cable caused by the spring. Check free play at foot operated parking brake lever BRAKE CABLES Rear brake cables, removing and installing Removing Remove both rear wheels. Remove center console --> 68 - INTERIOR EQUIPMENT. Before loosening nut - 1 -, measure dimension - a -.

136 Fig. 185: Removing Cable Sleeve From Mount Note measured value. Loosen nut until brake cables can be disengaged from compensator bracket. Remove cable sleeve from mount. Removing brake cable from spreader: Only possible with released brake cable. Fig. 186: Removing Locking Bolt For Adjustment Nut Of Parking Brake Remove locking bolt - arrow - for adjustment nut of parking brake.

137 Fig. 187: Pushing Brake Cable Nipple Against Retaining Spring In Spreader Downward Until Brake Cable Can Be Pulled Out Push brake cable nipple against retaining spring in spreader downward until brake cable can be pulled out. The right side is a mirror image, that means the brake cable nipple must be pushed upward. Remove brake cable from retainer on fuel tank. Remove brake cable from retainer on subframe and remove. Installing Installation is performed in the reverse sequence. Brake cable nipple must noticeably engage in spreader. Install brake cables into compensator bracket. Fig. 188: Removing/Installing Cable Sleeve From Mount

138 Check free play at foot operated parking brake lever. Front brake cable, removing and installing Removing Remove trim on drivers side --> 70 - INTERIOR TRIM. Remove center console --> 68 - INTERIOR EQUIPMENT. Remove sill panel trim --> 68 - INTERIOR EQUIPMENT. Fig. 189: Identifying Spring Plate Of Release Spring & Spring For Cable Compensation Press spring plate of release spring arrow - A - downward in order to compress the spring for cable compensation arrow - B -. Hold spring arrow - B - compressed. Fig. 190: Identifying Foot Operated Parking Brake Lever Secure compressed spring by e.g. sliding a drill through holes of the foot operated parking brake lever - arrow - and through the linked cable mounting.

139 BRAKE PEDAL, ASSEMBLY OVERVIEW 2006 Volkswagen Touareg Fig. 191: Identifying Brake Cable, Cable Mounting & Cable Sleeve Remove brake cable - A - from cable mounting of foot operated parking brake lever. Remove cable sleeve from mount. Fig. 192: Identifying Clip & Cable Sleeve Remove clip and disconnect brake cable from cable mounting. Remove cable sleeve from mount. Lift carpet and pull out brake cable. Installing Installation is performed in the reverse sequence. Remove transport protection device (drill) from foot operated parking brake lever. There will be an automatic length compensation of the brake cable caused by the spring. Check free play at foot operated parking brake lever.

140 Brake pedal, assembly overview Illustration for automatic transmission CAUTION: The path of the brake pedal must not be shortened via extra floor mats. Lubricate all bearings and contact surfaces with Grease G Fig. 193: Brake Pedal, Assembly Overview 1 - Mounting bracket for pedal assembly 2 - Self-locking nut, 20 Nm

141 Fig. 194: Release Tool T Volkswagen Touareg 3 - Pivot pin 4 - Brake pedal 5 - Ball socket 6 - Mount For ball head of brake servo push rod 7 - Support 8 - Bolt, 8 Nm 9 - Crash bar 10 - Pin 11 - Locking washer 12 - Bracket 13 - Bolt, 8 Nm 14 - Brake Light Switch F and Brake Pedal Switch F47 Removing and installing --> Brake Light Switch F and Brake Pedal Switch F47, removing and installing Vehicle from kw 48/06 do not have a brake light switch Separating brake pedal from brake booster Special tools, testers and auxiliary items required

142 Release Tool T10189 Remove trim on drivers side --> 70 - INTERIOR TRIM. Remove Brake Light Switch F and Brake Pedal Switch F47 --> Brake Light Switch F and Brake Pedal Switch F47, removing and installing. Fig. 195: Attaching Release Tool T10189 At Pressure Rod Mount In Brake Pedal And At Mounting Bracket Attach Release Tool T10189 at pressure rod mount in brake pedal and at mounting bracket. 1 - Brake pedal 2 - Pressure rod 3 - Retaining lugs Push brake pedal slightly toward brake booster and secure. Push Release Tool T10189 in direction of brake booster, hold at brake pedal (pedal must not move rearward at this point). The mounting retaining lugs will thereby be pressed off the ball head of the push rod Push Release Tool T10189 farther in direction of brake booster and pull brake pedal toward driver seat at the same time. (The brake pedal will thereby be pulled off the ball head of the push rod). Installing brake pedal to brake booster

143 Fig. 196: Removing/Installing Brake Pedal To Brake Booster Hold ball head of push rod in front of mounting and push brake pedal in direction of brake booster, so the ball head locates audibly. Further installation is in the reverse sequence to removal. Brake light switch, removing and installing --> Brake Light Switch F and Brake Pedal Switch F47, removing and installing. Brake Light Switch F and Brake Pedal Switch F47, removing and installing NOTE: Vehicle from kw 48/06 do not have a brake light switch. The signal is generated by the Brake Pressure Sensor 1 G201 and Brake Pressure Release Solenoid F84. Brake Light Switch must be removed for adjustment. Removing Fig. 197: Identifying Brake Light Switch

144 Remove trim on drivers side --> 70 - INTERIOR TRIM. Disconnect connector from brake light switch. The brake light switch must only be removed when plunger is pressed (brake pedal not operated), otherwise the retainer on the brake light switch will be damaged. Remove brake light switch by turning 45 to left. Brake light switch, installing, adjusting and locking To ensure secure installation, install brake light switch only once. Before installing the brake light switch, lube the plunger head with Polycarbamide Grease G A2. Before installing, pull out plunger completely. When installing brake light switch, brake pedal must always remain in rest position. The brake pedal may only be touched with the brake light switch plunger head during the entire assembly procedure. Fig. 198: Guiding Brake Light Switch Through Assembly Opening And Pressing It Against Pedal With Plunger Head Guide brake light switch through assembly opening and press it against pedal with plunger head. Then turn brake light switch 45 to the right until it noticeably engages. Connect brake light switch connector. Check function of brake light.

145 After adjusting the brake light switch ensure the brake pedal is resting on stop (rest position). Install drivers side trim --> 70 - INTERIOR TRIM BRAKES - HYDRAULIC COMPONENTS FRONT BRAKE CALIPER, SERVICING Brake caliper FN 3, servicing Install complete repair kit when servicing. Only use mineral spirits to clean brake parts. Apply thin coat of Assembly Paste G A2 to brake cylinders, pistons and seals. Fig. 199: Brake Caliper FN 3, Servicing Remove/Install Components

146 1 - Dust cap Install onto bleeder valve Secures brake pad wear indicator wiring 2 - Bleed valve, 12 Nm Apply a thin coat of Assembly Paste G A2 to the threads before screwing in. 3 - Caps Insert in bushing 4 - Guide pins, 30 Nm (18 ft lb) 5 - Bushing Insert in brake caliper 6 - Brake caliper 7 - Brake carrier Bolt to brake caliper 8 - Retaining spring Push under brake carrier and insert in both holes of brake caliper 9 - Sealing ring Removing and installing --> Brake caliper FN 3 piston, removing and installing 10 - Pistons Removing and installing --> Brake caliper FN 3 piston, removing and installing 11 - Protective cap Do not damage when installing piston Brake caliper FN 3 piston, removing and installing Special tools, testers and auxiliary items required

147 Fig. 200: Identifying Trim Removal Wedge 3409 Trim Removal Wedge 3409 Fig. 201: Piston Resetting Tool T10145 Piston Resetting Tool T10145 Fig. 202: Assembly Device For Protective Cap T10146/5

148 Assembly Tool for Protective Cap T10146/1 Removing Fig. 203: Removing Piston From Brake Caliper Using Compressed Air Remove piston from brake caliper using compressed air. Place a wooden board into the recess of the caliper housing so it is not damaged. Fig. 204: Prying Off Protective Cap From Brake Caliper Using Trim Removal Wedge 3409 Pry off protective cap from brake caliper using Trim Removal Wedge A - Protective covers

149 Fig. 205: Removing Seal Using Trim Removal Wedge 3409 Remove seal using Trim Removal Wedge When removing, make sure that surface of cylinder is not damaged. Installing The surface of the piston and seal must only be cleaned with mineral spirits and then dried. Thinly coat piston and seal with Assembly Paste G A2 before inserting. Install sealing ring in brake caliper. Fig. 206: Inserting Protective Cap Into Assembly Tool T10146/4 Insert protective cap - A - onto Assembly Tool for Protective Cap T10146/1-1 -.

150 Fig. 207: Identifying Protective Cap T10146/1 & Piston Resetting Tool T10145 Press the protective cap with the Assembly Tool for Protective Cap T10146/1-1 - and the Piston Resetting Tool T into the brake caliper applying equal pressure all around. Check seating of protective caps: Fig. 208: Pulling Protective Cap From Brake Caliper By Hand Protective cap must no longer be able to be pulled from brake caliper by hand.

151 Fig. 209: Pressing Piston Lightly Against Protective Cap And Lock It Into Position With Trim Removal Wedge 3409 Carefully install the protective cap onto the piston, and then secure it in this position using the Trim Removal Wedge Do not angle piston, to avoid damaging the seal sleeve. Blow compressed air (max. 3 bar) on to protective cap Protective cap springs onto piston. A - Protective covers Fig. 210: Pressing Piston Into Brake Caliper Using Piston Resetting Tool T10145 Press piston into brake caliper using Piston Resetting Tool T Outer sealing lip of protective cap will then engage in piston groove. Brembo 17" and 18" brake caliper, servicing Install complete repair kit when servicing.

152 Only use mineral spirits to clean brake parts. Apply thin coat of Assembly Paste G A2 to brake cylinders, pistons and seals. Brake caliper with PR no. 1LC and ILF Fig. 211: Brake Caliper With PR No. 1LC And ILF Remove/Install Components 1 - Dust cap Install onto bleeder valve Secures brake pad wear indicator wiring 2 - Bleed valve, 12 Nm Apply a thin coat of Assembly Paste G A2 to the threads before screwing in.

153 Brake caliper with PR no. 1LE 2006 Volkswagen Touareg SW Brake caliper 4 - Seal for 34/30 mm piston Removing and installing --> Piston for Brembo 17" and 18" brake caliper, removing and installing 5 - Seal for 36/34 mm piston Removing and installing --> Piston for Brembo 17" and 18" brake caliper, removing and installing 6 - Seal for 38 mm piston Removing and installing --> Piston for Brembo 17" and 18" brake caliper, removing and installing 7-34/30 mm piston Removing and installing --> Piston for Brembo 17" and 18" brake caliper, removing and installing First apply thin coat of Assembly Paste G A2 on piston 8-36/34 mm piston Removing and installing --> Piston for Brembo 17" and 18" brake caliper, removing and installing First apply thin coat of Assembly Paste G A2 on piston 9-38 mm piston Removing and installing --> Piston for Brembo 17" and 18" brake caliper, removing and installing First apply thin coat of Assembly Paste G A2 on piston 10 - Protective cap for 34/30 mm piston Do not damage when installing piston 11 - Protective cap for 36/34 mm piston Do not damage when installing piston 12 - Protective caps for 38 mm piston Do not damage when installing piston 13 - Brake line, 17 Nm

154 Fig. 212: Brake Caliper With PR No. 1LE Remove/Install Components 1 - Dust cap Install onto bleeder valve Secures brake pad wear indicator wiring 2 - Bleed valve, 12 Nm Apply a thin coat of Assembly Paste G A2 to the threads before screwing in. SW Brake caliper 4 - Sealing ring

155 Removing and installing --> Piston for Brembo 17" and 18" brake caliper, removing and installing 5-46 mm piston Removing and installing --> Piston for Brembo 17" and 18" brake caliper, removing and installing First apply thin coat of Assembly Paste G A2 on piston 6 - Protective cap Do not damage when installing piston Piston for Brembo 17" and 18" brake caliper, removing and installing Removal and installation of pistons is identical on the various brake calipers. Special tools, testers and auxiliary items required Fig. 213: Identifying Trim Removal Wedge 3409 Trim Removal Wedge 3409 Fig. 214: Piston Resetting Tool T10145

156 Piston Resetting Tool T10145 Removing Fig. 215: Identifying Piston Resetting Tool T10145, Wood Blocks, Wooden Board Remove pistons out individually of brake caliper housing using compressed air. Only one piston can be removed at a time. When doing this, hold the opposing piston in the caliper housing using the Piston Resetting Tool T a -. Block the other pistons, e.g. using wood blocks - b -. In addition, place a wooden board - c - in front of the piston resetting tool so that the piston will not be damaged when removed. Fig. 216: Removing Seal With Trim Removal Wedge 3409 Remove seal with Trim Removal Wedge When removing, make sure that surface of cylinder is not damaged. Installing

157 The surface of the piston and seal must only be cleaned with mineral spirits and then dried. Thinly coat piston and seal with Assembly Paste G A2 before inserting. Fig. 217: Inserting Oil Seal Into Brake Caliper Housing Insert oil seal into brake caliper housing. Fig. 218: Installing Protective Cap On Piston Install protective cap on piston.

158 Fig. 219: Using Equal Pressure To Push Piston Into Brake Caliper Housing Using equal pressure, push piston into brake caliper housing. The protective cap must be seated properly in the groove, push slightly farther if necessary. REAR BRAKE CALIPER, SERVICING Brake caliper FN 44, servicing Install complete repair kit when servicing. Only use mineral spirits to clean brake parts. Apply thin coat of Assembly Paste G A2 to brake cylinders, pistons and seals.

159 Fig. 220: Brake Caliper FN 3, Servicing Remove/Install Components 1 - Dust cap Install onto bleeder valve Secures brake pad wear indicator wiring 2 - Bleed valve, 12 Nm Apply a thin coat of Assembly Paste G A2 to the threads before screwing in. 3 - Caps Install in bushing

160 4 - Guide pins, 30 Nm (18 ft lb) 5 - Bushing Install in brake caliper 6 - Brake caliper 7 - Brake carrier Bolt to brake caliper 8 - Retaining spring Push under brake carrier and insert in both holes of brake caliper 9 - Sealing ring Removing and installing --> Brake caliper FN 44 piston, removing and installing 10 - Pistons Removing and installing --> Brake caliper FN 44 piston, removing and installing 11 - Protective cap Do not damage when installing piston Brake caliper FN 44 piston, removing and installing Special tools, testers and auxiliary items required Fig. 221: Identifying Trim Removal Wedge 3409

161 Trim Removal Wedge 3409 Fig. 222: Piston Resetting Tool T10145 Piston Resetting Tool T10145 Fig. 223: Assembly Device For Protective Cap T10146/5 Assembly Device for Protective Cap T10146/1 Removing

162 Fig. 224: Removing Piston From Brake Caliper Using Compressed Air Force piston from brake caliper using compressed air. Place a wooden board into the recess of the caliper housing so it is not damaged. Fig. 225: Prying Off Protective Cap From Brake Caliper Using Trim Removal Wedge 3409 Pry off protective cap from brake caliper using Trim Removal Wedge A - Protective covers

163 Fig. 226: Removing Seal Using Trim Removal Wedge 3409 Remove seal using Trim Removal Wedge When removing, make sure that surface of cylinder is not damaged. Installing The surface of the piston and seal must only be cleaned with mineral spirits and then dried. Thinly coat piston and seal with Assembly Paste G A2 before inserting. Install sealing ring in brake caliper. Fig. 227: Inserting Protective Cap Into Assembly Tool T10146/4 Insert protective cap - A - into Assembly Tool T10146/4-1 -.

164 Fig. 228: Identifying Protective Cap With The Assembly Tool T10146/4 & Piston Resetting Tool T10145 Press the protective cap with the Assembly Tool T10146/4-1 - and the Piston Resetting Tool T into the brake caliper applying equal pressure all around. Ensure protective caps are seated: Fig. 229: Identifying Protective Cap Protective cap must no longer be able to be pulled from brake caliper by hand.

165 Fig. 230: Pressing Piston Lightly Against Protective Cap And Lock It Into Position With Trim Removal Wedge Press piston lightly on to protective cap and then secure it in this position using e.g. Trim Removal Wedge Do not angle piston, to avoid damaging the seal sleeve. Blow compressed air (max. 3 bar) on to protective cap Protective cap springs onto piston. A - Protective covers Fig. 231: Pressing Piston Into Brake Caliper Using Piston Resetting Tool T10145 Press piston into brake caliper using Piston Resetting Tool T Outer sealing lip of protective cap will then engage in piston groove. Brembo 17" brake caliper, servicing Install complete repair kit when servicing.

166 Only use mineral spirits to clean brake parts. Apply thin coat of Assembly Paste G A2 to brake cylinders, pistons and seals. Brake caliper with PR no. 1KF Fig. 232: Brake Caliper With PR No. 1KF Remove/Install Components 1 - Dust cap Install onto bleeder valve 2 - Bleed valve, 12 Nm Apply a thin coat of Assembly Paste G A2 to the threads before assembling. SW 10

167 3 - Brake caliper 4 - Seal for 28 mm piston Removing and installing --> Rear brake caliper piston, removing and installing 5 - Seal for 30 mm piston Removing and installing --> Rear brake caliper piston, removing and installing 6-28 mm piston Removing and installing --> Rear brake caliper piston, removing and installing First apply thin coat of Assembly Paste G A2 on piston 7-30 mm piston Removing and installing --> Rear brake caliper piston, removing and installing Apply thin coat on piston beforehand 8 - Protective caps for 28 mm piston Do not damage when installing piston 9 - Protective caps for 30 mm piston Do not damage when installing piston 10 - Connecting line, 17 Nm 11 - Torx bolt 12 - Protective plate Brake caliper with PR no. 1KQ

168 Fig. 233: Brake Caliper With PR No. 1KQ Remove/Install Components 1 - Dust cap Install onto bleeder valve 2 - Bleed valve, 12 Nm Apply a thin coat of Assembly Paste G A2 to the threads before screwing in. SW Brake caliper 4 - Sealing ring

169 Removing and installing --> Rear brake caliper piston, removing and installing 5-44 mm piston Removing and installing --> Rear brake caliper piston, removing and installing First apply thin coat of Assembly Paste G A2 on piston 6 - Protective cap Do not damage when installing piston Rear brake caliper piston, removing and installing Removal and installation of pistons is identical on the various brake calipers. Special tools, testers and auxiliary items required Fig. 234: Identifying Trim Removal Wedge 3409 Trim Removal Wedge 3409 Fig. 235: Piston Resetting Tool T10145

170 Piston Resetting Tool T10145 Removing Fig. 236: Identifying Resetting Tool, Wood Blocks & Wooden Board Remove piston from brake caliper housing, one at a time, using compressed air. Only one piston can be pressed out at a time. Secure opposite piston in brake caliper housing using piston resetting tool - a -. Block the other pistons, e.g. using wood blocks - b -. In addition, place a wooden board - c - in front of the piston resetting tool so that the piston will not be damaged when pressed out. Fig. 237: Removing Seal With Trim Removal Wedge 3409 Remove seal with Trim Removal Wedge When removing, make sure that surface of cylinder is not damaged. Installing

171 The surface of the piston and seal must only be cleaned with mineral spirits and then dried. Thinly coat piston and seal with Assembly Paste G A2 before inserting. Fig. 238: Inserting Oil Seal Into Brake Caliper Housing Insert oil seal in brake caliper housing. Fig. 239: Installing Protective Cap On Piston Install protective cap on piston.

172 Remove the bleeder valve from one of the front brake calipers. Connect and bleed Brake Pressure Gauge Bar VAG 1310 A Volkswagen Touareg Fig. 240: Using Equal Pressure To Push Piston Into Brake Caliper Housing Push piston into brake caliper housing using constant pressure. The protective cap must be seated properly in the groove, push slightly farther if necessary. PRESSURE LEAK TEST Pressure leak test Special tools, testers and auxiliary items required Fig. 241: Brake Pressure Gauge V.A.G 1310 A Brake Pressure Gauge Bar VAG 1310 A Test conditions: Brake system (hydraulic unit, brake hoses, brake lines and brake calipers) operating properly and free of leaks.

173 Apply pressure to brake pedal until the gauge indicates a pressure of 50 bar. The pressure must not drop by more than 4 bar during the test period of 45 seconds. Replace master cylinder if pressure drops greatly. BLEEDING BRAKING SYSTEM Bleeding braking system Description covers bleeding of brake system using the Brake Charger/bleeder Unit VAS 5234 and Brake Pedal Actuator VAG 1869/2. NOTE: Bleeding the braking system on vehicles with ABS is carried out as for vehicles with conventional braking systems. Only use new brake fluid conforming to US-Norm FMVSS 116 DOT 4. Genuine VW/Audi brake fluid conforms to this specification. Brake fluid is poisonous. Due to its caustic nature, it must also never be brought into 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 off spillages, by using plenty of water. There must be a positive pressure of 2 bar to bleed the hydraulic unit. Bleeding brake system using Brake Charger/bleeder Unit VAS 5234 or Brake Pedal Actuator VAG 1869/2 Special tools, testers and auxiliary items required Fig. 242: Brake Charger/Bleeder Unit VAS 5234 Brake Charger/bleeder Unit VAS 5234 or

174 Fig. 243: Brake Pedal Actuator VAG 1869/2 Brake Pedal Actuator VAG 1869/2 Extraction Device Upgrade Kit VAG 1869/4 NOTE: If one chamber of the brake fluid reservoir has run completely empty (e.g. leak in the brake system), the brake system must be pre-bled first. Pre-bleed: There are two bleeder valves installed on Brembo brake calipers Always bleed at both bleeder valves. Bleed at outer bleeder valve first. Connect Brake Charger/bleeder Unit VAS 5234 or Brake Pedal Actuator VAG 1869/2. Bleeding sequence: 1 - Bleed left front and right front brake caliper together simultaneously 2 - Bleed left rear and right rear brake caliper together simultaneously With bleeder bottle hoses attached, leave bleeder valves open long enough that brake fluid exits without bubbles. Then hydraulic unit must be bled once more via function "Basic setting" using Vehicle Diagnosis, Testing info. System VAS Initiate basic setting (to bleed brake system): Vehicle Diagnosis, Testing info. System VAS 5051, connecting and selecting functions --> Connecting VAS 5051 and selecting functions. Then, brake system must be bled normally

175 After bleeding brake system, basic setting for Brake Pressure Sensor 1 G201 must be performed. Bleeding (normal): Adhere strictly to work sequence when bleeding brake system. There are two bleeder valves installed on Brembo brake calipers Always bleed at both bleeder valves. Bleed at outer bleeder valve first. Connect Brake Charger/bleeder Unit VAS 5234 or VAG Open bleeder valves in the prescribed sequence and bleed brake caliper. 1 - Right rear brake caliper 2 - Left rear brake caliper 3 - Right front brake caliper 4- Front left brake caliper Use suitable bleeder hose. It must fit tightly on bleeder valve so that no air gets into brake system. With bleeder bottle hose attached, leave bleeder valves open long enough that brake fluid exits without bubbles. Subsequent bleeding A second mechanic is required to assist: Depress brake pedal forcefully and hold. Open bleeder valve at brake caliper. Press brake pedal down until the pedal stops. Close bleeder valve with pedal depressed. Release brake pedal slowly. This bleeding procedure must be performed 5 times per brake caliper. Bleeding sequence: 1 - Right rear brake caliper 2 - Left rear brake caliper 3 - Right front brake caliper

176 4- Front left brake caliper A road test must be performed after bleeding. During this, at least one ABS assisted stop must be performed! Changing brake fluid (every 2 years) Brake fluid, changing --> 01 - MAINTENANCE ASSEMBLY OVERVIEW: BRAKE BOOSTER/MASTER BRAKE CYLINDER Assembly Overview: Brake booster/master brake cylinder NOTE: Use only new brake fluid. Observe information on brake fluid reservoir!

177 Fig. 244: Assembly Overview: Brake Booster/Master Brake Cylinder 1 - Mounting bracket for pedal assembly 2 - Self-locking nut, 25 Nm Always replace after removal 3 - Brake pedal 4 - Gasket For brake booster 5 - Tandem brake booster

178 On gasoline engines, vacuum is supplied from intake manifold. Vehicles with gasoline engine and automatic transmission are equipped with a brake system vacuum pump. On Diesel engines, a vacuum pump is installed for vacuum creation. Functional check: With engine switched off, depress brake pedal firmly several times (to deplete vacuum). Depress and hold brake pedal with average foot pressure and start engine. If brake booster is working properly, pedal will be felt to give noticeably under foot (booster assistance becomes effective). Replace as a unit in the event of malfunction (previously, check all vacuum lines). Removing and installing --> Brake booster, removing and installing 6 - Sealing ring 7 - Brake Booster Membrane Position Sensor G420 Removing and installing --> Brake Booster Membrane Position Sensor G420, removing and installing 8 - Snap ring 9 - Sealing ring 10 - Self-locking nut, 25 Nm Always replace after removal 11 - Brake line, 14 Nm Master brake cylinder/primary piston circuit to hydraulic control unit Identification at hydraulic unit - DK Brake line, 14 Nm Master brake cylinder/secondary piston circuit to hydraulic unit Identification at hydraulic unit - SK Brake Pressure Sensor 1 G201 Removing and installing --> Brake Pressure Sensor 1 G201, removing and installing 14 - Bracket

179 To left front brake caliper 16 - Master brake cylinder Cannot be serviced. Replace as complete unit if malfunctioning. Removing and installing --> Brake master cylinder, removing and installing 17 - Sealing plugs Moisten with brake fluid and install into brake fluid reservoir 18 - Brake fluid reservoir 19 - Cap 20 - Vacuum hose Insert into brake booster 21 - Sealing plugs Connection for vacuum hose Brake Booster Membrane Position Sensor G420, removing and installing Removing Remove plenum chamber cover --> 64 - GLASS, WINDOWS. Disconnect connector from brake booster membrane position sensor. Fig. 245: Identifying Circlip In Groove Pry circlip out of groove - arrow - and remove brake booster membrane position sensor from brake

180 Installing Installation is performed in the reverse order of removal. Brake Pressure Sensor 1 G201, removing and installing The brake pressure sensor is located on the brake master cylinder. Removing Remove master brake cylinder --> Removing Remove Brake Pressure Sensor 1 G201. Installing Installation is performed in the reverse order of removal. Tightening torque Brake Pressure Sensor 1 G Nm Bleed brake system --> Bleeding braking system. After bleeding brake system, Brake Pressure Sensor 1 G201 basic setting must be performed. Vehicle Diagnosis, Testing info. System VAS 5051, connecting and selecting functions --> Connecting VAS 5051 and selecting functions. VACUUM SUPPLY FOR BRAKE BOOSTER Brake System Vacuum Pump V192 - assembly overview Only on vehicles with gasoline engine and automatic transmission

181 Fig. 246: Brake System Vacuum Pump V192 - Assembly Overview 1 - Brake Booster Pressure Sensor G294 Removing and installing --> Brake Booster Pressure Sensor G294, removing and installing 2 - Vacuum hose To brake booster 3 - Brake Booster Relay J569 Removing and installing Wiring diagrams 4 - Check valve

182 Functional check 5 - Clamp Replace 6 - Clip 7 - Buffer stop 8 - Brake System Vacuum Pump V192 Removing and installing --> Brake System Vacuum Pump V192, removing and installing 9 - Buffer stop 10 - Bracket 11 - Nut 12 - Bolt Brake System Vacuum Pump V192, removing and installing It is not possible to service the Brake System Vacuum Pump V192. If there is a malfunction, replace Brake System Vacuum Pump V192. Removing Fig. 247: Identifying Connector & Vacuum Hose Disconnect connector Disconnect vacuum hose from Brake System Vacuum Pump Brake System Vacuum Pump V192.

183 Fig. 248: Removing Brake System Vacuum Pump V192 Upward From Bracket Disengage clip in direction of arrow and remove. Remove Brake System Vacuum Pump V192 upward from bracket. Installing Installation is performed in the reverse order of removal. Brake Booster Pressure Sensor G294, removing and installing Removing Remove plenum chamber cover --> 64 - GLASS, WINDOWS. Fig. 249: Identifying Connector Disconnect connector

184 Fig. 250: Prying On Sensor Brake Booster Pressure Sensor G294 Carefully pry on sensor Brake Booster Pressure Sensor G294 and remove. Installing Installation is performed in the reverse order of removal. Checking check valve: Valve must allow air to flow in direction of arrow. Valve must remain closed in opposite direction. Observe correct installation position. BRAKE MASTER CYLINDER, REMOVING AND INSTALLING Brake master cylinder, removing and installing Special tools, testers and auxiliary items required Fig. 251: Brake Charger/Bleeder Unit VAS 5234

185 BRAKE BOOSTER, REMOVING AND INSTALLING 2006 Volkswagen Touareg Brake Charger/bleeder Unit VAS 5234 Removing Remove plenum chamber cover --> 64 - GLASS, WINDOWS. Remove engine compartment seal and cover strip in area of brake booster. Remove facing wall of plenum chamber. Place sufficient lint-free cloths in plenum chamber in the area of the brake master cylinder. Extract as much brake fluid as possible from brake fluid reservoir using Brake Charger/bleeder Unit VAS 5234 or Extraction Device Upgrade Kit VAG 1869/4. Disconnect electrical connector from float warning indicator sensor. Disconnect electrical connector from brake pressure sensor. On vehicles with manual transmission, disconnect clutch master cylinder supply hose and seal with plug. Remove brake fluid reservoir, press the engagement straps toward outside at reservoir and simultaneously pull brake fluid reservoir out of sealing plugs. Remove left front brake line from retainer on master brake cylinder. Disconnect brake lines from master brake cylinder and seal brake lines using Sealing Plugs 1H A from repair kit. Remove brake master cylinder nuts. Carefully take brake master cylinder out of brake booster. Installing Installation is performed in the reverse order of disassembly. Observe the following points when installing: When installing together the brake master cylinder and brake booster, make sure that the push rod is correctly located in the brake master cylinder. O-ring between master brake cylinder and brake booster is present. Bleed braking system --> Bleeding braking system After bleeding brake system, basic setting for Brake Pressure Sensor 1 G201 must be performed. Vehicle Diagnosis, Testing info. System VAS 5051, connecting and selecting functions --> Connecting VAS 5051 and selecting functions.

186 Brake booster, removing and installing Special tools, testers and auxiliary items required Fig. 252: Brake Charger/Bleeder Unit VAS 5234 Brake Charger/bleeder Unit VAS 5234 Removing Remove trim on drivers side --> 70 - INTERIOR TRIM. Remove brake light switch/brake pedal switch --> Brake Light Switch F and Brake Pedal Switch F47, removing and installing. Remove brake light switch bracket. Disconnect brake pedal from brake booster --> Separating brake pedal from brake booster. Fig. 253: Removing/Installing Brake Pedal To Brake Booster Remove support on mounting bracket through which pressure rod of brake booster runs. Remove plenum chamber cover --> 64 - GLASS, WINDOWS.

187 Remove facing wall of plenum chamber. Disconnect electrical connector from brake pressure sensor. Disconnect electrical connector from float warning indicator sensor. Remove ground cable from ground point on body behind E-box, remove wiring harness from retainer behind brake booster and lay aside. Fig. 254: Removing/Installing E-Box Cover Remove E-box from left plenum chamber from retainer and lay as far as possible aside --> 97 - WIRING. Place sufficient lint-free cloths in plenum chamber in the area of the brake master cylinder. Extract as much brake fluid as possible from brake fluid reservoir using Brake Charger/bleeder Unit VAS 5234 or Extraction Device Upgrade Kit VAG 1869/4. On vehicles with manual transmission, disconnect clutch master cylinder supply hose and seal with plug. Remove brake fluid reservoir, press the engagement straps toward outside at reservoir and simultaneously pull brake fluid reservoir out of sealing plugs. Remove left front brake line from retainer on master brake cylinder. Disconnect brake lines from master brake cylinder and seal brake lines using Sealing Plugs 1H A. Remove brake master cylinder nuts. Carefully take brake master cylinder out of brake booster. Remove Brake Booster Membrane Position Sensor --> Brake Booster Membrane Position Sensor G420, removing and installing. Pull vacuum hose out of brake booster. Remove brake lines from the 3 compartment bracket at brake booster. Disconnect left front brake line at separating point in left front wheel housing.

188 Fig. 255: Removing Nuts From Brake Booster Remove nuts from brake booster. Carefully remove brake booster from plenum chamber. Installing Installation is performed in the reverse order of removal. Observe the following points when installing: Installing brake pedal to brake booster Hold ball head of push rod in front of mounting and push brake pedal in direction of brake booster, so the ball head locates audibly. After installing, bleed brake system --> Bleeding braking system and clutch. After bleeding brake system, basic setting for Brake Pressure Sensor 1 G201 must be performed. Vehicle Diagnosis, Testing info. System VAS 5051, connecting and selecting functions --> Connecting VAS 5051 and selecting functions. Brake light switch, removing and installing --> Brake Light Switch F and Brake Pedal Switch F47, removing and installing. BRAKE LINE REPAIRS Brake line repairs Flare brake lines with 5 mm outer diameter using Flaring Tool VAS 6056 without damaging coating. In this way, brake lines can be inexpensively partially replaced in certain cases. Work with brake line kit VAG 1356 is not permitted because of the coating and diameter of black brake lines.

189 NOTE: Brake lines must not be bent more than 90, otherwise they kink or deform causes unacceptable constriction in the line. Disconnect brake lines preferably at vehicle floor. Position of intermediate pieces should be selected so that they cannot rub against moving parts. Do not lubricate spindle, clean only with mineral spirits. Special tools, testers and auxiliary items required Fig. 256: Flaring Tool VAS 6056 Flaring Tool VAS 6056 Brake Charger/bleeder Unit VAS 5234

190 Fig. 257: Brake Line Repairs Tools Listing of individual tools: Item Tool Tool number 1 Flaring Tool (including Flaring Jaws VAS 6056/6) VAS 6056/1 2 Tube cutter VAS 6056/2 3 Brake line shearing tool * See note VAS 6056/3 4 Self-grip pliers with plastic clamping jaws VAS 6056/4 5 Line bending tool VAS 6056/5 6 SW6 angle screwdriver -

191 *The threaded pins (in shaft and at sides) are set and must not be adjusted! Flaring tool - assembly overview 7 Flaring jaws VAS 6056/7 Fig. 258: Flaring Tool - Assembly Overview 1 - Upper part of flaring tool Remove to change flaring jaws 2 - Hand grip mount Must be removed to reach retaining screw for upper part

192 3 - Retaining screw For upper part of flaring tool 4 - Flaring jaws threaded pins Center and hold the flaring jaws 2 mm hex socket head 5 - Flaring jaws Various Assembly instructions Flaring jaws assembly instructions: Flaring jaws assembly instructions: Fig. 259: Flaring Jaws Assembly Instructions: VAS 6056/6 (dark) for black brake lines VAS 6056/7 (light) for green brake lines NOTE: The arrow on the rounded side of the flaring jaws must face toward edge of housing and the straight side of the flaring jaws must be installed toward spindle, otherwise flared head will not be formed correctly. Instructions Remove affected brake line at brake caliper or wheel brake cylinder and collect escaping brake fluid and dispose of it correctly.

193 Fig. 260: Disconnecting Brake Line At Appropriate Location With Line Cutter Disconnect brake line at appropriate location (straight, accessible part) with line cutter Remove piece to be replaced. Lubricate brake line surface. Fig. 261: Brake Line Clamped In Self-Grip Pliers Clamp brake line in self-grip pliers so that 50mm of the plastic clamping jaws show. Clamp shearing tool in a drill and place it on brake line. Shear coating from brake line at a slow drill RPM and with light pressure against the line. The length of the sheared-off portion is determined by the stop in the shearing tool. Remove shearing tool from brake line and remove shearing remains.

194 Fig. 262: Identifying Self-Grip Pliers, Tube Fitting And Brake Line Remove self-grip pliers and tube fitting - D - from brake line. Fig. 263: Sliding Brake Line Against Stop In Flaring Tool Slide brake line - B - against stop - A - in flaring tool. NOTE: Brake line must contact stop when the screws are tightened, otherwise flare will not be formed correctly. Secure the brake line in the flaring tool until it cannot be moved any more. Rotate stop - A - up and tighten flaring tool screws diagonally with angle screw driver - C -.

195 Fig. 264: Identifying Stop In Down Position Fig. 265: Turning Spindle To Stop In Flaring Tool Turn spindle until it stops. Turn spindle back. Loosen screws. Remove brake line from flaring tool, clean and check brake line and flared head. Briefly rinse part of brake line remaining in vehicle. Connect Brake Charger/bleeder Unit VAS 5234, place bleeder container hose on flanged head of brake line and run Brake Charger/bleeder Unit VAS 5234 briefly until some brake fluid runs through. Blow out brake line to be installed with compressed air.

196 Fig. 266: Connecting Brake Lines With Union Connect the brake lines with a union - E -. Assemble brake line. Bleed braking system