46 - brakes - mechanical components

46 - BRAKES - MECHANICAL COMPONENTS

FRONT BRAKES FN3

Front brakes, servicing

Fig. 38: Exploded View Of Front Brakes FN3 Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:� Install complete repair kit � After replacing brake pads, depress brake pedal several times firmly to

properly seat brake pads in their normal operating position. � When siphoning brake fluid, always use a bleeder bottle that is used

exclusively for brake fluid. Brake fluid is poisonous. NEVER siphon brake fluid with your mouth!

2008 Audi A6 Quattro

BRAKES Brake System


BRAKES Brake System

FIXYOURCAR

1:37:07 AM

FIXYOURCAR

1:37:11 AM Page 1

1 - Brake disc cover

2 - Flange bolt, 10 Nm

� M6x12

3 - Brake hose

� Do not remove brake hose when replacing brake pad

4 - Bracket

� Bolt to brake caliper housing

5 - Hex bolt, 10 Nm

6 - Spring clamp

7 - Brake line

� Bracket-side torque specification, 17 Nm

� Brake caliper-side torque specification, 12 Nm

� Install into brake caliper housing

� Installed together with brake hose, held against hex nut of brake hose.

� Make sure that lugs are properly seated in grooves in bracket.

8 - Harness connector

9 - Ribbed bolt, 190 Nm

� If re-using, clean ribs

10 - Brake carrier

� Bolt to wheel bearing housing

11 - Brake pads

� Wear limit --> Technical data

NOTE:� The inner surface (with tension spring) is indicated by an arrow. The arrow

must point in the rotation direction of the brake rotor when driving forward. If improperly installed, noises could result.

� Before installing brake pads, clean pad guide surface and coat it with a


BRAKES Brake System

FIXYOURCAR

1:37:07 AM

12 - Retaining spring

� Before installing brake pads, clean pad guide surface and coat it with a film of Polycarbamide grease G 052 142 A2 .

� Insert in both holes of brake caliper housing

13 - Brake disc

� Wear limit --> Technical data � Must always be replaced together on both sides of axle

� Remove brake caliper before removing

� Thickness --> Brakes

� Allocation --> Brakes

14 - Bolt

� Torque specification 5 Nm

15 - Wheel bolts

� Mounting wheels --> 44 - WHEELS, TIRES, VEHICLE ALIGNMENT

film of Polycarbamide grease G 052 142 A2 . � The backing plate of outer brake pad is equipped with an adhesive film.

Peel off protective foil before installing. � Left and right front brake wear indicators � When wear limit is reached (limit: 3 mm), a warning lamp comes in

instrument cluster � Must always be replaced together on both sides of axle � Removing and installing --> Brake pads, removing and installing � Checking brake pad thickness: 405 � Different versions

NOTE:� Before installing new brake pads, thoroughly clean the brake calipers of

contaminants (grease-free). When doing so, pay particular attention to removing any remaining adhesive foil on outer brake pad contact surfaces.

NOTE:� Retaining spring must be pressed under brake carrier after it is inserted in

both holes. If improperly installed, the wear of the outer brake pad cannot be adjusted, thereby increasing brake pedal travel.


BRAKES Brake System

FIXYOURCAR

1:37:07 AM

16 - Brake caliper housing

� To replace brake pads, unfasten from brake carrier

� Brake caliper, servicing --> Brake caliper, servicing

17 - Guide pins, 30 Nm (18 ft lb)

18 - Concealment cap

� Remove

Brake pads, removing and installing

Fig. 39: Identifying Special Tools - Brake Pads, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC.


BRAKES Brake System

FIXYOURCAR

1:37:07 AM

Special tools, testers and auxiliary items required

� Torque wrench V.A.G 1331


� Brake pedal actuator V.A.G 1869/2

� Piston resetting tool T10145


Removing

� Raise vehicle.

� Remove wheels.

Fig. 40: Removing Caps Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove caps - arrows -.

NOTE:� When removing, mark brake pads that will be used again. Install in the

same position, otherwise braking effect will be uneven! � The brake disc is secured with a Phillips head screw.


BRAKES Brake System

FIXYOURCAR

1:37:07 AM

Fig. 41: Brake Wear Pad Indicator Connector Courtesy of VOLKSWAGEN UNITED STATES, INC.

� For vehicles with brake wear pad indicator, disconnect connector - 1 -.

� Lift fixing latch somewhat on lower part of connector - 2 - and turn 90°.

� Pull lower part of connector from holder.

Fig. 42: Removing Brake Pad Retaining Spring From Brake Caliper Housing Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Using screwdriver, pry off brake pad retaining spring from brake caliper housing and remove.


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Fig. 43: Removing/Installing Caliper Guide Pins Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove both guide pins from brake caliper.

� Remove brake caliper housing and support it so that the weight of the brake caliper does not stress or damage brake hose.

� Remove brake pads from brake caliper housing or from brake carrier.

Installing

Fig. 44: Pressing Piston Back Into Caliper Housing Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Press piston back.

Clean brake caliper with mineral spirits exclusively.

NOTE:� Before inserting new brake pads, press the piston back into the cylinder

using the piston resetting tool. Before pushing back the piston, siphon some of the brake fluid out of the brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.

CAUTION: Brake fluid is poisonous. NEVER siphon brake fluid with your mouth!


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Fig. 45: Inserting Brake Pad With Retaining Spring Into Brake Caliper Housing (Piston) Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Insert brake pad with retaining spring into brake caliper housing (piston).

Fig. 46: Inserting Brake Pad With Retaining Spring Into Brake Caliper Housing (Piston) Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove protective foil from backing plate of outer brake pad.

� Install outer brake pad on brake carrier.

� Attach brake caliper housing to brake carrier and fasten guide pins to 25 Nm.

� Install both protective caps.

� Install retaining spring in brake caliper housing.

NOTE:� The inner surface (with tension spring) is indicated by an arrow. The arrow

must point in the rotation direction of the brake rotor when driving forward. If improperly installed, noises could result.

NOTE:� Retaining spring must be pressed under brake carrier after it is inserted in

both holes. If improperly installed, the wear of the outer brake pad cannot be adjusted, thereby increasing brake pedal travel.


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

� Check brake fluid level, and fill if necessary.

FRONT WHEEL BRAKE FNRG60


� After installing brake pads, depress brake pedal several times firmly to properly seat brake pads in their normal operating position.

NOTE:� Install complete repair kit � After replacing brake pads, depress brake pedal several times firmly to

properly seat brake pads in their normal operating position. � When siphoning brake fluid, always use a bleeder bottle that is used

exclusively for brake fluid. Brake fluid is poisonous. NEVER siphon brake fluid with your mouth!

� Check brake caliper for ease of movement by moving it sideways.


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Fig. 47: Exploded View Of Front Brakes FNR-G60 Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Brake pads


NOTE:� The inner surface (with tension spring) is equipped with a cable for wear

indicator. � Must always be replaced together on both sides of axle � Before installing brake pads, clean pad guide surface and coat it with a

film of Polycarbamide grease G 052 142 A2 . � Removing and installing --> Brake pads, removing and installing � Checking brake pad thickness: 405


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

2 - Brake carrier


3 - Ribbed bolt, 196 Nm

� If re-using, clean the ribs

� M14x1.5x 38

4 - Bushing

� Insert in brake caliper housing

5 - Guide pins, 30 Nm (18 ft lb)

6 - Concealment cap

� Remove

� Hook in cable for wear indicator

7 - Brake disc



� Coat contact surfaces between brake disc and wheel hub with Polycarbamide grease G 052 142 A2 . --> 44 - WHEELS, TIRES, VEHICLE ALIGNMENT

� Allocation --> Brakes � Thickness --> Brakes

8 - Wheel bolts


9 - Bolt


� Different versions


contaminants (grease-free). When doing this, pay particular attention to the cleanliness of the brake pad contact surfaces.


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

10 - Spring clamp

11 - Brake line connection to brake hose, 12 Nm

12 - Brake line



� Hose must be installed free of twists


13 - Brake line connection to brake caliper, 17 Nm

14 - Bracket


� Hook in brake line

15 - Bolt



� Do not allow to hang from brake hose, rather suspend it from body using bundling wire

� Except for "replacing brake pads" --> Brake pads, removing and installing and "servicing front brake caliper" , no other repairs should be performed on brake caliper



� Observe correct installed position.


NOTE:� After hooking into both studs, the retaining spring must be pressed under

the brake carrier. If improperly installed, the wear of the outer brake pad cannot be adjusted, thereby increasing brake pedal travel.


BRAKES Brake System

FIXYOURCAR

1:37:08 AM





� Brake pedal actuator V.A.G 1869/2

� Piston resetting tool T10145


Removing



BRAKES Brake System

FIXYOURCAR

1:37:08 AM

� Raise vehicle.

� Remove wheels.

� The brake disc is secured with a bolt - 1 -.

Fig. 49: Prying Off Retaining Spring Courtesy of VOLKSWAGEN UNITED STATES, INC.

� To pry off retaining spring, guide a screwdriver between retaining spring and brake pad retaining spring.

� Ensure surface of brake pad retaining spring is not scratched or damaged.

same position, otherwise braking effect will be uneven! � The brake disc is secured with a Phillips head screw.

NOTE:� The spring is tensioned, keep hands protected.


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Fig. 50: Retainer Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Retainer, see - arrow - � Using screwdriver, pry off brake pad retaining spring from brake caliper housing and remove.

Fig. 51: Disconnecting Brake Wear Indicator Connector Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Disconnect brake wear indicator connector

� Release connector from retainer using a screwdriver and simultaneously turn connector 90°

� Pull connector out upward and unhook line

Fig. 52: Unhooking Brake Line From Retainer Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Unhook brake line - arrow - from retainer


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Fig. 53: Removing Protective Caps Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove - 1 - caps.

Fig. 54: Securing Brake Caliper Housing To Brake Carrier With Both Guide Pins Courtesy of VOLKSWAGEN UNITED STATES, INC.


� Remove brake caliper housing and set aside so that the weight of the brake caliper does not burden or damage the brake hose.



Installing


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Fig. 55: Pressing Piston Back Into Caliper Housing Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Press piston back.

Fig. 56: Setting Brake Pad With Retaining Spring And Wear Indicator Into Brake Caliper Housing (Piston) Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Set brake pad with retaining spring and wear indicator into brake caliper housing (piston).

NOTE:� Before inserting new brake pads, press the piston back into the cylinder

using the piston resetting tool. Before pushing back the piston, siphon some of the brake fluid out of the brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.



BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Fig. 57: Setting Outer Brake Pad With Retaining Springs Into Brake Caliper Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Set outer brake pad - 2 - onto brake caliper.

Fig. 58: Securing Brake Caliper Housing To Brake Carrier With Both Guide Pins Courtesy of VOLKSWAGEN UNITED STATES, INC.


� Make sure brake hose is installed free of twists.


NOTE:� Insert brake pads into brake caliper and mount them together onto brake

carrier and brake disc.


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Fig. 59: Inserting Brake Pad Retaining Spring At Upper Housing Retaining Spring And At Retaining Tab Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Insert brake pad retaining spring - arrows - at upper housing retaining spring and at retaining tab...

Fig. 60: Pressing Lower Housing Retaining Spring By Hand And Simultaneously In Brake Pad Retaining Spring Courtesy of VOLKSWAGEN UNITED STATES, INC.

� ...then press lower housing retaining spring by hand and simultaneously in brake pad retaining spring in


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

direction of - arrow -.

Fig. 61: Checking Housing Retaining Spring Is Engaged Correctly In Brake Pad Retaining Spring And Upper/Lower Arm Is Engaged Correctly At Brake Carrier Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Check whether housing retaining spring is engaged correctly in brake pad retaining spring and whether upper and lower arm is engaged correctly at brake carrier.


� Connect connector for wear indicator and hook line into dust cap and cover.



FRONT BRAKES 2FNR 42 AL


NOTE:� After engaging retaining springs in both studs, the retaining spring must

be pressed under the brake carrier. If improperly installed, the wear of the outer brake pad cannot be adjusted, thereby increasing brake pedal travel.


NOTE:� Always install complete repair kit � After replacing brake pads, depress brake pedal firmly several times with


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Fig. 62: Identifying Front Brakes 2FNR 42 AL Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Brake pads


vehicle stationary so that the brake pads are properly seated in their normal operating position.

� When siphoning brake fluid, always use a bleeder bottle that is used exclusively for brake fluid. Brake fluid is poisonous. NEVER siphon brake fluid with your mouth!

� Check brake caliper for ease of movement by moving it sideways.

NOTE:� The inner surface (with tension spring) is equipped with a cable for wear


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

2 - Brake carrier


3 - Ribbed bolt

� Torque specification, 190 Nm

� If re-using, clean the ribs

� M14x1.5x 38

4 - Bushing

� Insert in brake caliper housing

5 - Guide pins

Torque specification, 30 Nm

6 - Concealment cap

� Remove

� Hook in cable for wear indicator

7 - Brake disc



indicator. � The backing plate of the outer brake pad is equipped with an adhesive

film. Peel off protective foil before installing. � Before installing brake pads, clean pad guide surface and coat it with a

film of Polycarbamide grease . � Different versions � Must always be replaced together on both sides of axle � Removing and installing --> Brake pads, removing and installing � Checking brake pad thickness: 4E


contaminants (grease-free). When doing so, pay particular attention to removing any remaining adhesive foil on outer brake pad contact surfaces.


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

� Coat contact surfaces between brake disc and wheel hub with polycarbamide grease G 052 142 A2.

8 - Wheel bolts

� Mount wheels and Tires Guide

9 - Brake line connection to brake hose


10 - Brake line





11 - Brake line connection to brake caliper


12 - Bracket



13 - Bolt M 8x16



� When doing work, do not allow to hang from brake hose, rather suspend it from body using bundling wire

� Except for "replacing brake pads" --> Brake pads, removing and installing and "servicing front brake caliper" , no other repairs should be performed on brake caliper

� Install hose so it is not twisted


� Observe correct installed position.




BRAKES Brake System

FIXYOURCAR

1:37:08 AM


Removing

� Raise vehicle.

� Remove wheels.

Fig. 63: Securing Brake Disc Using Wheel Bolt Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Secure brake disc using a wheel bolt - arrow -.

Fig. 64: Using Screwdriver To Pry Off Brake Pad Retaining Spring From Brake Caliper Housing Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Using screwdriver, pry off brake pad retaining spring from brake caliper housing and remove.


same position, otherwise braking effect will be uneven! � Observe the direction of rotation when installing brake disc arrow on

brake disc and installed location left or right.


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Fig. 65: Disconnecting Brake Wear Indicator Connector Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Disconnect brake wear indicator connector - arrow - , see illustration.

Fig. 66: Releasing Connector From Retainer Using Screwdriver And Simultaneously Turning Connector 90° Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Release connector from retainer using a screwdriver and simultaneously turn connector 90°

� Pull connector out upward and unhook line

NOTE:� Spring is tensioned, protect with a glove or cloth.


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Fig. 67: Unhooking Brake Line From Retainer Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Unhook brake line from retainer

Fig. 68: Removing Caps Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove caps - 1 -.

Fig. 69: Attaching Brake Caliper Housing To Brake Carrier And Fastening Guide Pins Courtesy of VOLKSWAGEN UNITED STATES, INC.


BRAKES Brake System

FIXYOURCAR

1:37:08 AM


� Remove brake caliper housing and set aside so that the weight of the brake caliper does not burden or damage brake hose.



Installing

Fig. 70: Pressing Pistons Back Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Press both pistons back.

NOTE:� The brake pad with wear indicator sits inside. � Brake carrier must be removed to replace brake pads.

NOTE:� Press piston back into caliper housing using resetting tool before

inserting new brake pads. Before pushing back the piston, siphon some of the brake fluid out of the brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.



BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Fig. 71: Setting Brake Pad With Retaining Spring And Wear Indicator Into Brake Caliper Housing (Piston) Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Set brake pad with retaining spring and wear indicator into brake caliper housing (piston).

Fig. 72: Setting Outer Brake Pad With Retaining Springs Into Brake Caliper Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Set outer brake pad - 2 - onto brake caliper.

NOTE:� Insert brake pads into brake caliper and mount them together onto brake

carrier and brake disc.


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Fig. 73: Attaching Brake Caliper Housing To Brake Carrier And Fastening Guide Pins Courtesy of VOLKSWAGEN UNITED STATES, INC.



� Make sure brake hose is installed free of twists.

� Install retaining spring in brake caliper housing.


� Connect the connector for wear indicator and hook line into dust cap and cover.

� Install wheels --> 44 - WHEELS, TIRES, VEHICLE ALIGNMENT


REAR BRAKES, ELECTROMECHANICAL PARKING BRAKE (EPB)

Rear brake, servicing

Rear wheel brake with automatic adjustment




NOTE:� Install complete repair kit


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Fig. 74: Rear Brake, Servicing Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Self-locking bolt (Torx 30), tightening torque, 12 Nm

2 - Electromechanical parking brake actuator

� Electromechanical parking brake control module, removing and installing --> Electro-Mechanical Parking Brake Control Module J540 , removing and installing

� Actuator, removing and installing --> Electromechanical parking brake actuator, removing and installing

3 - Sealing ring

� Always replace


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

4 - Self-locking bolt, 35 Nm

� Always replace

� When loosening and tightening, counter-hold at guide pin

5 - Spacer

6 - Brake hose

� To brake caliper, tightening torque 12 Nm

� Do not disconnect brake line when changing brake pads

� Ensure retaining tabs are seated correctly in bracket.

� Install hose without twisting


� Do not remove brake hose when replacing brake pad

� Brake caliper, servicing --> Rear brake caliper piston, removing and installing

� It is possible to install brake carrier with brake caliper

8 - Brake carrier with guide pins and protective cap

� Supplied as pre-assembled replacement part with sufficient grease on guide pins

� If protective caps or guide pins are damaged, install repair kit. Use grease packet supplied to lubricate guide pins


9 - Brake pads


� Removing and installing --> Brake pads, removing and installing

� Checking brake pad thickness: 405


10 - Anti-rattle spring

� Always replace when pads are replaced

11 - Wheel bolts



BRAKES Brake System

FIXYOURCAR

1:37:08 AM

12 - Phillips-head bolt


13 - Brake disc


� To remove brake discs on 16" brake systems, brake carrier must be removed.


� Brake disc allocation --> Brakes

14 - Hex bolts, 10 Nm

15 - Brake shield

16 - Ribbed bolts

� M 12 x 1.5 x 60

� Always replace

� Lower connection: To tighten lower connection, adjust Torque Wrench V.A.G 1332 to 115 Nm. This tightening torque only applies in conjunction with Socket T40065 for left side and Socket T40066 for right side.

17 - Ribbed bolts

� M 12 x 1.5 x 60

� Always replace

� Upper connection: Torque specification 140 Nm.



BRAKES Brake System

FIXYOURCAR

1:37:08 AM





� Vehicle diagnostic, test and information system VAS 5051

� Socket T40065

� Socket T40066

Removing



BRAKES Brake System

FIXYOURCAR

1:37:08 AM

� Raise vehicle.

� Remove wheels.

Fig. 76: Data Link Connector (DLC) Courtesy of VOLKSWAGEN UNITED STATES, INC.

� With ignition off, connect Vehicle Diagnosis, Testing and Information System VAS 5051 to 16-pin diagnostic connector on vehicle and select parking brake with "Address word" 53.

same position, otherwise braking effect will be uneven! � Operating the electromechanical parking brake again after a long drive is

recommended. � Brake pad play is automatically adjusted every 1000 km if the EPB is not

operated in this distance. � The brake disc is secured with a Phillips head bolt.

NOTE:� Ignition on � Release parking brake � Coding check and reported if necessary. � DTC memory interrogated, errors shown corrected and DTC memory

erased.


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Fig. 77: Locating Control Module Identification With Code Indicated On Display Courtesy of VOLKSWAGEN UNITED STATES, INC.

Shown on VAS 5051 display:

� Select function "53 - Parking brake".

� Select function "04 - Basic setting".

� Select function "10 to code after replacing control module".

Fig. 78: Identifying Diagnostic Operation System VAS 5051A (Prompt For Entering Display Group Appears In Display Zone & Input Keypad Appears In Display Zone) Courtesy of VOLKSWAGEN UNITED STATES, INC.


� The request to enter a display group number appears in display field - 1 -.

� An entry keypad is shown in display field - 2 -.

When installing new or old brake pads

� Using entry keypad, enter in display field - 2 - the "7" for "Display group number one and confirm by pressing " Q button. (Reset pistons)

� To exit entry template, press green Arrow button at lower left.


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Fig. 79: Identifying Brake Disc Secure Bolt Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove tires

Fig. 80: Identifying Attachment Bolts For Brake Caliper Housing Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove attachment bolts from brake caliper housing, to do so counter-hold guide pins.

� Remove brake caliper sideways or hang on body.

� Remove brake pads

� Remove guide clamps

� Press brake pistons back by hand.

NOTE:� Ignition off � The brake disc is secured with a Phillips head bolt - 1 -.

NOTE:� Actuator or brake system connector must not be disconnected.

(otherwise, a fault will be saved) � Do not pull on brake hose or electrical wiring.


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Remove brake carrier:

Fig. 81: Using Socket T40065 For Left Side And Socket T40066 For Right Side To Remove Brake Carrier Lower Connection Courtesy of VOLKSWAGEN UNITED STATES, INC.

� To remove brake carrier lower connection, use Socket T40065 for the left side and Socket T40066 for the right side.

Installing


Fig. 82: Inserting Pad Retaining Springs Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Insert brake pad retaining springs

NOTE:� To remove brake discs on 16" brake systems, brake carrier must be

removed. � Check brake discs, replace if necessary.


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Fig. 83: Identifying Brake Pads, Guide Clips & Brake Caliper Housing Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Insert brake pads.

Fig. 84: Identifying Brake Pads Are Located Correctly In Anti-Rattle Springs Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Make sure brake pads are located correctly in anti-rattle springs - arrows -.

NOTE:� The next step only applies to vehicles on which the brake carrier must be

disassembled for removal.


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Fig. 85: Using Socket T40065 For Left Side And Socket T40066 For Right Side To Remove Brake Carrier Lower Connection Courtesy of VOLKSWAGEN UNITED STATES, INC.

� To install lower connection, use Socket T40065 or Socket T40066.

Fig. 86: Identifying Attachment Bolts For Brake Caliper Housing Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Secure brake caliper housing using new self-locking bolts.

NOTE:� The repair kit includes four self-locking hex bolts which must be installed

in all cases.


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Fig. 87: Identifying Diagnostic Operation System VAS 5051A (Prompt For Entering Display Group Appears In Display Zone & Input Keypad Appears In Display Zone) Courtesy of VOLKSWAGEN UNITED STATES, INC.


� The request to enter a display group number appears in display field - 1 -.

� An entry keypad is shown in display field - 2 -.

� Using entry keypad, enter in display field - 2 - the "6" for "Display group number one and confirm by pressing " Q button. (guide pistons together)

� To exit entry template, press green Arrow button at lower left.



BRAKE PEDAL (MANUAL TRANSMISSION), ASSEMBLY OVERVIEW

Brake pedal (manual transmission), assembly overview

� Lubricate all bearing and contact surfaces with lubricant part no.Lubricant G 000 450 02 .

CAUTION: The path of the brake pedal must not be shortened via extra floor mats.


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Fig. 88: Brake Pedal (Manual Transmission), Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Mounting bracket for pedal assembly

� Manual transmission illustration

2 - Pin

3 - Securing clip (spring steel)

4 - Torx flange bolt, 10 Nm

5 - Brake pedal

� Removing and installing --> Brake pedal, removing and installing


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

6 - Ball socket formed in mount

7 - Wheel hub support

� For ball head of brake servo push rod

8 - Pressure or over-center spring

� When installing, spring mount to pedal support, black spring mount to clutch pedal

9 - Bushing

10 - Clutch lever stop

� Different stops

� Black: 2.4L gasoline engines (140 mm)

� White: other engines (150 mm)


12 - Clutch master cylinder

13 - Clutch pedal




17 - Clutch sensor bracket

18 - Pin

Brake pedal, removing and installing



BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Fig. 89: Torque Wrench V.A.G 1410 Courtesy of VOLKSWAGEN UNITED STATES, INC.


Removing

� Remove trim on drivers side. --> 68 - INTERIOR EQUIPMENT

� Remove brake light switch --> Brake light switch, removing and installing. � Disconnect brake pedal from brake booster

� Remove Torx flange bolt - 3 -.

Fig. 90: Brake Pedal, Removing And Installing Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Loosen retainer - 1 - on right side and remove pins - 5 -.


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

� Remove brake pedal.

Installing

Installation is in reverse order of removal, with special attention to the following:

Joining 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.

� Adjust brake light switch/brake pedal switch --> Brake light switch, removing and installing.

BRAKE PEDAL (AUTOMATIC TRANSMISSION), ASSEMBLY OVERVIEW

Brake pedal (automatic transmission), assembly overview

� Lubricate all bearing and contact surfaces with lubricant part no.Lubricant G 000 450 02 .

CAUTION: The path of the brake pedal must not be shortened via extra floor mats.


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Fig. 91: Brake Pedal (Automatic Transmission), Assembly Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Mounting bracket for pedal assembly

� Illustration for automatic transmission

2 - Locking washer

3 - Pin

4 - Brake pedal

� Removing and installing --> Brake pedal, removing and installing

5 - Ball socket in mount


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

6 - Wheel hub support

� For ball head of brake servo push rod


� Only tighten bolts when securing clips are in place.

8 - Locking washer

9 - Plug

� Heavy coating in direction of bulkhead

MOUNTING BRACKET

Mounting bracket, removing and installing





BRAKES Brake System

FIXYOURCAR

1:37:08 AM



Removing

� Remove trim on drivers side. --> 68 - INTERIOR EQUIPMENT

� Move adjustable steering column all the way back (opposite direction of travel)

Fig. 94: Disconnecting Accelerator Module Connector Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Disconnect accelerator module connector - 1 -.


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Fig. 95: Identifying Multi -Point Socket Head Bolts & Brake Light Switch Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Disconnect brake light switch - 2 - and remove --> Brake light switch, removing and installing. � Disconnect brake pedal from brake booster

Fig. 96: Disconnecting Connector On Clutch Pedal Switch F36 Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Disconnect connector - 1 - on Clutch Pedal Switch F36.

Fig. 97: Disconnecting Connector For Clutch Pedal Switch F194


BRAKES Brake System

FIXYOURCAR

1:37:08 AM

Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Disconnect connector - 1 - for Clutch Pedal Switch F194.


� Remove multi-point socket head bolts - 1 -.

Fig. 99: Removing Multi-Point Socket Head Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove multi-point socket head bolts - 1 - and - 3 -

Allocation of multi-point socket head bolts , tightening torque 25 Nm.

� Remove tower brace - 2 -.

NOTE:� Do not remove brake fluid reservoir.


BRAKES Brake System

FIXYOURCAR

1:37:09 AM

Fig. 100: Removing Brake Fluid Reservoir Locking Bolt & Disconnecting Connector Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove brake fluid reservoir locking bolt - 1 -.

� Disconnect connector - 2 -

Fig. 101: Removing Fasteners Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Press reservoir to side and remove fasteners - 1 -.

Fig. 102: Removing Fasteners


BRAKES Brake System

FIXYOURCAR

1:37:09 AM

Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Press reservoir to side and remove fasteners - 1 -.

Fig. 103: Removing Hex Socket Head Bolt & Mounting Bracket Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove hex socket head bolt - 1 - , tightening torque 25 Nm.

� Remove mounting bracket.

Remove gas pedal

Installing


� First thread pins into mounting bracket and attach brake booster.


NOTE:� Only affects vehicles with manual transmission.


BRAKES Brake System

FIXYOURCAR

1:37:09 AM

� Then install multi-point socket head bolts - 1 -

Clip brake pedal together with 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.

� Adjust brake light switch/brake pedal switch --> Brake light switch, removing and installing.

ELECTROMECHANICAL PARKING BRAKE (EPB), COMPONENT OVERVIEW

Electromechanical parking brake (EPB), component overview

Fig. 105: Electromechanical Parking Brake (EPB), Component Overview Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Parking Brake Contact Switch F321


BRAKES Brake System

FIXYOURCAR

1:37:09 AM

� Pull --> Close button

� Press --> Open button

� Component location: in center console

� Removing and installing --> Parking Brake Contact Switch F321 , removing and installing

2 - LED (light emitting diode) display for closed parking brake

3 - EPB system malfunction indicator (yellow)

� If parking brake malfunctions, a yellow symbol and the brake! appears in instrument cluster display.

4 - Electromechanical parking brake

� Display for attained tension and dynamic deceleration

� Indicator light comes on when parking brake is closed and ignition is on.

� After switching off ignition, indicator light stays on for about 30 seconds.

� If parking brake is closed with ignition off, indicator light comes on for about 30 seconds.

� The indicator light must go out when parking brake is released.

� If indicator light blinks continuously after parking brake is closed, braking force is not sufficient to secure vehicle against rolling. Observe the following:

� If incline is too large to switch off, the Vehicle incline too large also appears.

� If parking brake malfunctions, a yellow symbol and the brake! appears in the instrument cluster display.

5 - Left Parking Brake Motor V282

� Removing and installing --> Electromechanical parking brake (EPB), rear brake caliper

� Electromechanical parking brake control module, removing and installing --> Electro-Mechanical Parking Brake Control Module J540 , removing and installing

� Electromechanical parking brake actuator, removing and installing --> Electromechanical parking brake actuator, removing and installing

6 - Electro-Mechanical Parking Brake Control Module J540

� Component location: In right rear side panel, below tool set

� Removing and installing --> Hydraulic unit, removing and installing

7 - Right Parking Brake Motor V283

� Removing and installing --> Rear brake caliper piston, removing and installing

8 - Acoustic signal


BRAKES Brake System

FIXYOURCAR

1:37:09 AM

� Warning when operating while driving

� Warning when malfunction in system is detected

Electro-Mechanical Parking Brake Control Module J540 , removing and installing




Removing

� Remove right rear side trim in luggage compartment --> 70 - INTERIOR TRIM

Fig. 107: Removing Nuts, EPB Control Module With Plug Connector & Pulling Locking Slide Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove nuts - 1 - , tightening torque 10 Nm

� Remove EPB control module with plug connector - 2 -.

� Pull locking slide - a - in direction of arrow - b - and remove connector.


BRAKES Brake System

FIXYOURCAR

1:37:09 AM

Installing


� If control module is replaced, select "Replace" function for respective control module in "Guided Fault Finding".

Vehicle diagnostic, test and information system VAS 5051

Electromechanical parking brake actuator, removing and installing




Fig. 109: VAS 5051 Vehicle Diagnosis, Testing and Information System Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Vehicle diagnostic, test and information system VAS 5051

Removing


BRAKES Brake System

FIXYOURCAR

1:37:09 AM

� Raise vehicle.

� Remove wheels.

Fig. 111: Removing Both Actuator Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

NOTE:� Ignition on � Release parking brake � Coding check and reported if necessary. � DTC memory interrogated, errors shown corrected and DTC memory

erased. � Ignition off

NOTE:� Ignition must be switched off for at least 30 seconds when disconnecting

connector! � Clean entire area around connector and actuator/brake caliper.

Fig. 110: Disconnecting Actuator Connector Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Disconnect actuator connector - 1 -.


BRAKES Brake System

FIXYOURCAR

1:37:09 AM

� Remove both actuator bolts (Torx 30) - 1 -.

Fig. 112: Removing Actuator Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove actuator in direction of - arrow -

Fig. 113: Removing Sealing Ring With Suitable Tool Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Remove sealing ring with a suitable tool.

Ensure ring groove of the seal and contact surface of parking brake actuator do not become damaged.

� Clean ring groove and contact surfaces if dirty. Only use brake cleaner

Installing

� Install new seal

� Turn brake caliper adjuster screw back a bit.

NOTE:� Do not use any tools with sharp edges.


BRAKES Brake System

FIXYOURCAR

1:37:09 AM

Fig. 114: Positioning Actuator Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Item - 1 - position actuator as shown

Fig. 115: Identifying Item 2 Rotate Actuator So Bolt Hole And Threads In Brake Caliper Housing Are Brought Into Alignment Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Item - 2 - rotate actuator so bolt hole - a - and threads in brake caliper housing - b - are brought into alignment.

Ensure parking brake actuator is seated flush against brake caliper.

NOTE:� This makes it easier to install the actuator.

NOTE:� Ensure seal is seated correctly


BRAKES Brake System

FIXYOURCAR

1:37:09 AM

Fig. 116: Attaching Both Actuator Bolts Courtesy of VOLKSWAGEN UNITED STATES, INC.

� Attach both actuator bolts (Torx 30). Torque specification 12 Nm.

Position bolts by hand and screw in a few turns. If threads are damaged, entire brake caliper must be replaced!

� Install connector.


After replacing actuator, basic setting 10 must be performed with the vehicle diagnostic tester in the EPB function.

For this, use Vehicle diagnostic, test and information system VAS 5051.

� Then select basic section 10 under "Function" --> Vehicle Diagnostic, Testing and Information System VAS 5051 , connecting and selecting function

NOTE:� Only insert connector by hand to avoid damaging it. � Ensure connectors on vehicle side and actuator side are free of dirt and

damage.


BRAKES Brake System

FIXYOURCAR

1:37:09 AM

46 - brakes - mechanical components

Documents