mK5 Jetta brakes

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    Apply a thin coat of assemblypaste G 052 150 A2 to the threadsbefore screwing in.

    3 - Caps

    Insert into bushing

    4 - Guide pins, 30 Nm

    5 - Bushing

    Insert in brake caliper

    6 - Brake caliper

    7 - Brake carrier

    Bolt to brake caliper

    8 - Retaining spring

    Insert with both ends in holes ofbrake caliper

    9 - Sealing ring

    Removing and installing 47-1,Brake caliper FN 3 piston,removing and installing

    10 - Piston

    Removing and installing 47-1,Brake caliper FN 3 piston,removing and installing

    Apply thin coat of assembly pasteG 052 150 A2 to piston before

    inserting11 - Protective cap

    Removing and installing 47-1,Brake caliper FN 3 piston,removing and installing

    Do not damage when insertingpiston

    Brake caliper FN 3 pist on, removing and inst alling

    Special tools, testers and auxiliary items required

    Page 2 / 11Front brake caliper, servicing

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    Disassembly wedge 3409

    Piston resetting tool T 10145

    Assembly device for protective cap T 10146/6

    Removing

    - Force piston from brake caliper using compressed air.

    Page 3 / 11Front brake caliper, servicing

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    - Thinly coat piston and seal with assembly paste G 052150 A2 before inserting.

    - Install sealing ring in brake caliper.

    - Insert protective cap - A - into assembly tool T 10146/6 -1 - .

    - Press protective cap with assembly tool - 1 - and pistonresetting tool - 2 - into brake caliper so that it contacts thebrake caliper all around.

    Check seating of protective caps:

    - Protective cap must no longer be able to be pulled frombrake caliper by hand.

    Page 5 / 11Front brake caliper, servicing

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    - Press piston lightly against the protective cap and lock itinto position, e.g. with trim removal wedge - 2 - .

    Do not angle piston, to avoid damaging the sealsleeve.

    - Blow protective cap on with pressurized air (max. 3 bar) -1 - . Protective cap springs on to piston.

    - Press piston into brake caliper using piston resetting tool- 1 - .

    The outer seal lip of the protective cap thereby slips into

    the groove on the piston.

    Brake caliper FNR-G, servicing

    When carrying out repairs, install all parts supplied inrepair kit.

    Only use mineral spirits to clean brake parts.

    Apply thin coat of assembly paste G 052 150 A2 tobrake cylinders, pistons and seals.

    Page 6 / 11Front brake caliper, servicing

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    1 - Dust cap

    Install onto bleeder valve

    2 - Bleeder valve, 12 Nm

    Apply a thin coat of assemblypaste G 052 150 A2 to the threadsbefore screwing in.

    3 - Caps

    Insert into bushing

    4 - Guide pins, 30 Nm

    5 - Bushing

    Insert in brake caliper

    6 - Brake caliper

    Must not be bolted apart

    Page 7 / 11Front brake caliper, servicing

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    7 - Brake carrier

    Bolt to brake caliper

    8 - Retaining spring

    Insert in brake pad retaining springand press below brake carrier

    9 - Sealing ring

    Removing and installing 47-1,Brake caliper FNR-G piston,removing and installing

    10 - Piston

    Removing and installing 47-1,Brake caliper FNR-G piston,removing and installing

    Apply thin coat of assembly pasteG 052 150 A2 to piston beforeinserting

    11 - Protective cap

    Removing and installing 47-1,

    Brake caliper FNR-G piston,removing and installing

    Do not damage when insertingpiston

    Brake caliper FNR-G piston, removing and inst alling

    Special tools, testers and auxiliary items required

    Disassembly wedge 3409

    Page 8 / 11Front brake caliper, servicing

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    - Remove seal using Trim Removal Wedge 3409 .

    When removing, make sure that the surface of cylinder isnot damaged.

    Installing

    - The surface of the piston and seal must only be cleanedwith mineral spirits and then dried.

    - Thinly coat piston and seal with assembly paste G 052150 A2 before inserting.

    - Install sealing ring in brake caliper.

    - Insert protective cap - A - into assembly tool T 10146/1 -1 - .

    Page 10 / 11Front brake caliper, servicing

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    - Press protective cap using assembly tool - 1 - and pistonresetting tool - 2 - into brake caliper so that it contacts thebrake caliper all around.

    Check seating of protective caps:- Protective cap must no longer be able to be pulled frombrake caliper by hand.

    - Lightly press piston against protective cap with anextension and ratchet adapter - 1 - and hold it there, inthat position.

    Do not angle piston, to avoid damaging the seal

    sleeve.- Blow protective cap on with pressurized air (max. 3 bar) -2 - . Protective cap springs on to piston.

    - Press piston with hand into brake caliper, possibly pushback slightly with piston resetting tool.

    The outer seal lip of protective cap slips into groove onpiston.

    Page 11 / 11Front brake caliper, servicing

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    47 - 2

    Rear brake caliper, servicing

    When carrying out repairs, install all parts supplied inrepair kit.

    Only use mineral spirits to clean brake parts.

    New brake calipers are filled with brake fluid andpre-bled.

    Apply thin coat of assembly paste G 052 150 A2 tobrake cylinders, pistons and seals.

    When carrying out repairs it is essential toappropriately pre-bleed the brake calipers (withoutbrake pads) before installing in the vehicle 47-2,Pre-bleeding brake caliper .

    CII 41 brake assembly overview:

    15 inch from KW 32/04

    Page 1 / 7Rear brake caliper, servicing

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    1 - Brake caliper with parking brakecable lever

    Replace brake caliper if leaking atparking brake cable lever

    Pre-bleed brake caliper afterrepairing 47-2, Pre-bleedingbrake caliper

    2 - Dust cap

    3 - Bleeder valve, 10 Nm

    Apply a thin coat of assemblypaste G 052 150 A2 to the threadsbefore screwing in.

    4 - Hex bolt, self-locking , 35 Nm

    Replace

    When loosening and tightening

    Page 2 / 7Rear brake caliper, servicing

    Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru Volkswagen, Skoda, Seat, Audi

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    counter hold on guide pin

    5 - Guide pin with st epping

    Shorter than item 6

    Grease before pulling on protectivecap

    6 - Guide pins

    Longer than item 5

    Grease before pulling on protectivecap

    7 - Protective cap

    Pull onto brake carrier and guidepin

    8 - Brake pad with damper

    Supplied as replacement partassembled with sufficient greaseon guide pins

    If protective caps or guide pins aredamaged use repair kit. Use

    supplied grease packet to lubricateguide pins.

    9 - Protective cap

    Pull outer sealing lip onto piston

    Removing and installing 47-2,Removing

    10 - Piston with automatic adjustment

    Removing and installing 47-2,Removing

    Apply thin coat of assembly pasteG 052 150 A2 to piston beforeinserting

    11 - Sealing ring

    Removing and installing 47-2,Removing

    Removing

    Page 3 / 7Rear brake caliper, servicing

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    purpose.

    - Remove seal using Trim Removal Wedge 3409 .

    Installing

    - The surface of the piston and seal must only be cleanedwith mineral spirits and then dried.

    - Thinly coat piston and seal with assembly paste G 052150 A2 before inserting.

    - Place protective seal with outer sealing lip on the piston.

    - Insert inner sealing lip in cylinder groove with assemblywedge 3409.

    Page 5 / 7Rear brake caliper, servicing

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    Hold piston in front of brake caliper for this procedure.

    - Screw piston into housing by turning knurled wheelclockwise.

    - Use special tool 10165/1 for assistance when installing.

    Insert reset and screw out tool so that collar makescontact on brake caliper.

    The automatic adjustment in brake caliper isdestroyed when piston is moved with piston resettingtool (e.g. T 10145) or foot brake is operated.

    Pre-bleeding brake caliper

    Page 6 / 7Rear brake caliper, servicing

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    - Open bleeder valve - arrow A - and fill with brake fluidusing standard bleeder bottle until brake fluid flows out ofthreaded hole (end of brake hose) - arrow B - withoutbubbles. Close bleeder valve.

    Position brake caliper as illustrated to pre-bleed.

    Page 7 / 7Rear brake caliper, servicing

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    47 - 3

    Pressure leak test

    Special tools, testers and auxiliary items required

    Brake pressure gauge 0-250 bar V.A.G 1310 A

    Adapter M 10 V.A.G 1310/6

    Test condi tions:

    Brake system (hydraulic unit, brake hoses, brake lines andbrake calipers) operating properly and free of leaks.

    - Remove bleeder valve at one front brake caliper.Connect Brake Pressure Gauge 0-250 Bar VAG1310Aand bleed.

    - Apply pressure to brake pedal until gauge indicates apressure of 50 bar. The pressure must not drop by morethan 4 bar during test period of 45 seconds. Replacemaster cylinder if pressure drops greatly.

    Page 1 / 1Pressure leak test

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    Bleeding (normal):

    Adhere st ri ct ly to work sequence when bleeding brakesystem.

    - Connect Brake filler/bleeder unit VAS 5234 .

    - Open bleeder valves in prescribed sequence and bleedbrake caliper.

    1 - Left front brake caliper

    2 - Right front brake caliper

    3 - Left rear brake caliper

    4 - Right rear brake caliper

    Use suit able bleeder hose. It must fit t ight ly on bl eedervalve so that no air can enter brake system.

    - With bleeder bottle hose attached, leave bleeder valveopen long enough that brake fluid exits without bubbles.

    Subsequent bleeding

    A second technician is required to assist:

    - Depress brake pedal forcefully and hold.

    - Open bleeder valve at brake caliper.

    - Press brake pedal down onto stop.

    - Close bleeder valve with pedal held down.

    - Release brake pedal slowly.

    This bleeding procedure must be performed 5 timesper brake caliper.

    Bleeding sequence:

    1 - Left front brake caliper

    2 - Right front brake caliper

    3 - Left rear brake caliper

    4 - Right rear brake caliper

    A road test must be performed aft er b leeding. Dur ingthis, at least one ABS regulation must be performed!

    - Install rear wheels.

    Torque specification for wheel bolts

    Page 3 / 4Bleeding braking system

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    .

    Repair Manual, Suspension, Wheels, Steering, RepairGroup 44, Torque specifications for wheel bolts

    Changing brake fluid (every 2 years)

    Changing br ake flui d

    Repair Manual, Maintenance

    Page 4 / 4Bleeding braking system

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    47 - 5

    Brake booster/brake master cyl inder, assembly

    overview Note:

    Use only new brake fluid. Observe information onbrake fluid reservoir!

    Pedal assembly

    Hex nut, self-locking , 25 Nm

    Replace each time

    Gasket

    For brake booster

    Page 1 / 7Brake booster/brake master cylinder, assembly overview

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    Brake booster

    On gasoline engines thevacuum required is takenfrom the intake manifold.

    Some vehicles with gasolineengine and automatictransmission are equippedwith a Brake SystemVacuum Pump V192 47-5, Brake system vacuumpump V192 .

    On vehicles with HBV, avacuum sensor is installed

    45-8, Brake BoosterVacuum Sensor G483 ,removing and installing

    Functional check:

    If faulty, replace completely.

    Removing and installing47-7, Brake booster,

    removing and installing

    Sealing ring

    Brake Booster Vacuum SensorG483

    Only on vehicles with HBV

    Removing and installing45-8, Brake Booster Vacuum

    Sensor G483 , removing andinstalling

    - With engine switched off,depress brake pedal firmlyseveral times (to exhaustthe vacuum in the unit).

    - Depress brake pedal with

    average foot pressure, holdand start engine. If boosterunit is working properly, thepedal will be felt to giveslightly under foot (boosterassist becomes effective).

    Page 2 / 7Brake booster/brake master cylinder, assembly overview

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    Brake master cylinder withoutbrake light swit ch

    Application ElectronicParts Catalog (ETKA)

    Cannot be repaired. If faulty,replace completely.

    Removing and installing47-6, Brake master cylinder,removing and installing

    Brake master cylinder with brakelight switch

    Application ElectronicParts Catalog (ETKA)

    Cannot be repaired. If faulty,replace completely.

    Removing and installing47-6, Brake master cylinder,removing and installing

    Brake light switch FIncludes Brake Pedal SwitchF47

    On vehicles before KW45/05, Brake Light Switch Fis located on brake pedal46-4, Brake pedal, assemblyoverview

    Removing and installing

    46-4, Brake pedal, assemblyoverview

    Inner Torx bol t, 5 Nm

    Heat shield

    Hex nut, self-locking , 25 Nm

    Replace each time it isremoved

    Brake line, 14 Nm

    Page 3 / 7Brake booster/brake master cylinder, assembly overview

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    Brake mastercylinder/secondary pistoncircuit to hydraulic unit

    Brake line, 14 Nm

    Brake mastercylinder/primary piston circuitto hydraulic unit

    Sealing plug

    Moisten with brake fluid andpress into brake fluidreservoir

    Brake fluid reservoir

    Cap

    Sealing plug

    Connection for vacuum hose

    Vacuum hose

    Insert into brake booster

    Check-valve, checking

    The check valve - A - must allow air through indirection of - arrow - .

    Check-valve must remain closed for oppositedirection.

    Page 4 / 7Brake booster/brake master cylinder, assembly overview

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    Observe correct installation position!

    Brake system vacuum pump V192

    Component location of Brake System Vacuum Pump V192is located on automatic transmission at front in direction oftravel.

    Servicing work on brake system vacuum pump V192 is notpossible. If there is a malfunction, replace Brake SystemVacuum Pump V192 .

    Can be checked in "Guided Fault Finding" using VAS5051

    Removing

    - Disconnect vacuum hose - 1 - from Brake SystemVacuum Pump V192 .

    - Disconnect harness connector - 2 - for Brake SystemVacuum Pump V192 .

    - Remove remaining harness connectors and wires frombracket - 3 - .

    - Remove - arrows - bracket - 3 - with Brake SystemVacuum Pump V192 .

    Page 5 / 7Brake booster/brake master cylinder, assembly overview

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    - Remove - arrows - Brake System Vacuum Pump V192- 1 - from bracket - 2 - .

    Installing

    Installation is in reverse order of removal.

    Torque specifications:

    Brake System Vacuum Pump V192 to bracket 8 NmBracket to automatic transmission 25 Nm

    Brake Light Swit ch F from KW 45/05, removing andinstalling

    On vehicles before KW 45/05, brake light switch waslocated on brake pedal.

    Removing

    - Remove engine cover.

    - On some vehicles, intake hose must be removed.

    - Disconnect connector - 1 - from Brake Light Switch F .

    - Remove bolt - 2 - from brake master cylinder.

    - Pull Brake Light Switch F - 3 - downward and off from

    Page 6 / 7Brake booster/brake master cylinder, assembly overview

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    the brake master cylinder and remove it from the retainingtab at the top - 4 - .

    Installing

    - Installation is in reverse order of removal.

    Tightening torque:

    Torx bolt to brake master cylinder 5 Nm

    Page 7 / 7Brake booster/brake master cylinder, assembly overview

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    47 - 6

    Brake master cylinder, removing and installing

    Special tools, testers and auxiliary itemsrequired

    Hose clamps up to 25 mm dia.3094

    Torque wrench V.A.G 1331

    Brake filler/bleeder unit V.A.G1869

    Brake filler/bleeder unit suctionadapter V.A.G 1869/4

    Page 1 / 3Brake master cylinder, removing and installing

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    Brake filler/bleeder unit VAS5234

    Removing - Note or request radio code on vehicles with coded radio ifnecessary.

    - Disconnect battery.

    Repair Manual, Electrical Equipment, Repair Group 27,Batteries, disconnecting and connecting

    - Battery, removing and installing.

    .

    Repair Manual, Electrical Equipment, Repair Group 27,Batteries, removing and installing

    - Remove battery carrier.

    - Place sufficient lint-free cloths in area of engine andtransmission.

    - Extract as much brake fluid as possible from brake fluidreservoir using Brake filler/bleeder unit VAS 5234 orextraction device V.A.G 1869/4 .

    For vehicles with manual transmission:

    - Disconnect clutch master cylinder supply hose - B -using Hose Clamps Up to 25 mm dia. 3094 .

    - Pull off supply hose - B - for clutch master cylinder.

    Page 2 / 3Brake master cylinder, removing and installing

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    Continued for all vehicles:

    - Disconnect connector - A - from floating warningindicator sensor.

    - Disconnect connector from Brake Light Switch F (only onvehicles from KW 45/05).

    - Remove brake fluid reservoir. To do this press lockingtabs on the reservoir outward and simultaneously pullbrake fluid reservoir out of sealing plugs.

    - Unfasten brake lines - 1 - at brake master cylinder andplug brake lines with sealing plugs from repair kit Part No.1H0 698 311 A.

    - Remove nuts - 2 - from main brake cylinder.

    - If present, remove heat shield.

    - Carefully take brake master cylinder out of brakebooster.

    Installing

    - Installation is in reverse order of removal.

    Observe the following points when installing:- When installing together the brake master cylinder andbrake booster, make sure that the push rod is correctlylocated in the brake master cylinder.

    - Bleed braking system 47-4, Bleeding braking system

    Torque specifications:

    Master brake cylinder at brake booster

    Use new nuts!

    25 Nm

    Brake lines to main brake cylinder 14 Nm

    Page 3 / 3Brake master cylinder, removing and installing

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    47 - 7

    Brake boos ter, removing and ins talling

    Special tools, testers and auxiliary itemsrequired

    Hose clamps up to 25 mm dia.3094

    Torque wrench V.A.G 1331

    Brake filler/bleeder unit V.A.G1869

    Brake filler/bleeder unit suctionadapter V.A.G 1869/4

    Page 1 / 5Brake booster, removing and installing

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    Continued for all vehicles:

    - Disconnect connector - A - from floating warningindicator sensor.

    - Disconnect connector from Brake Light Switch F (only onvehicles from KW 45/05).

    - Remove brake fluid reservoir. To do this press lockingtabs on reservoir outward and simultaneously pull brakefluid reservoir out of sealing plugs.

    - Unfasten brake lines - 1 - at brake master cylinder andplug brake lines with sealing plugs from repair kit Part No.1H0 698 311 A.

    - Remove nuts - 2 - from brake master cylinder.

    - If present, remove heat shield.

    - Carefully take brake master cylinder out of brakebooster.

    - Pull vacuum hose out of brake booster.

    For vehicles with manual transmission:

    - Remove cable - 1 - , unscrew mounting bracket - 2 -and lay it aside.

    Page 3 / 5Brake booster, removing and installing

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    Repair Manual, Manual Transmission, Repair Group 34,Selector mechanism, servicing

    Continued for all vehicles:- Remove trim on drivers side.

    Repair Manual, Body Interior, Repair Group 70,Instrument panel

    Brake light switch is no longer present on mounting bracketfrom KW 45/05.

    - Disconnect connector - 1 - from brake light switch.

    - Remove Brake Light Switch - 2 - by rotating 45 towardleft.

    - Remove air channel - 3 - .

    - Remove cover - 4 - .

    - Disconnect brake pedal from brake booster 46-4,Separating brake pedal from brake booster .

    Page 4 / 5Brake booster, removing and installing

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    - Remove nuts - 1 - from brake booster.

    - Loosen both upper nuts - 2 - from mounting bracket.

    - Carefully remove brake booster from vehicle.

    Installing

    - Installation is in reverse order of removal.

    Observe the following when installing:

    - Clip brake pedal together with brake booster Topic 46-4

    - After installing, bleed brakes 47-4, Bleeding brakingsystem and clutch.

    Only on vehicles up to KW 45/05:

    - Adjust brake light switch 46-4, Brake light switch F upto KW 45/05, removing, installing and adjusting .

    Torque specifications:

    Brake booster to foot pedal assembly/cross panel

    Use new nuts!

    25 Nm

    Master brake cylinder at brake booster

    Use new nuts! 25 Nm

    Brake lines to main brake cylinder 14 Nm

    Page 5 / 5Brake booster, removing and installing

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    47 - 8

    Brake line repairs

    Flare brake lines with 5 mm outer diameter using brake lineflaring appliance VAS 6056 without damaging coating. Inthis way, brake lines can be inexpensively partiallyreplaced in certain cases.

    Work with brake line kit V.A.B. 1356 is not permittedbecause of the coating and diameter of black brake lines.

    Note:

    Brake lines must not be bent more than 90 ,otherwise they kink or deform causes unacceptableconstriction 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 mineralspirits.

    Special tools, testers and auxiliary items required

    Brake line flaring appliance VAS 6056

    Brake filler/bleeder unit VAS 5234

    Page 1 / 7Brake line repairs

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    Listing of individual tools:

    Flaring appliance VAS 6056/1

    flaring jaws VAS 6056/6 arecontained in the flaring

    appliance VAS 6056/1

    Tube cutter VAS 6056/2

    Brake line shearing tool VAS6056/3

    The threaded pins (in shaftand at sides) are set andmust not be adjusted!

    Self-grip pl iers with plasticclamping j aws VAS 6056/4

    Page 2 / 7Brake line repairs

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    Line bending too l VAS 6056/5

    SW6 angle screwdr iver

    Flaring jaws VAS 6056/7

    Flaring tool, assembly overview

    Upper part of flaring tool

    Remove to change flaring jaws

    Hand grip mount

    Must be removed to reachretaining screw for upper

    part

    Retaining screw

    Page 3 / 7Brake line repairs

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    - Remove affected brake line at brake caliper or wheelbrake cylinder and collect escaping brake fluid and disposeof it correctly.

    - Disconnect brake line at appropriate location (straight,accessible part) with line cutter - 2 - .

    - Remove piece to be exchanged.

    - Lubricate brake line surface.

    - Clamp brake line in self-grip pliers - 4 - so that 50 mm ofthe plastic clamping jaws show.

    - Clamp shearing tool - 3 - in a drill and place it on brakeline.

    - Shear coating from brake line at a slow drill RPM andwith light pressure against the line.

    The length of the sheared-off portion is determined by thestop in the shearing tool.

    - Remove shearing tool from brake line and removeshearing remains.

    Page 5 / 7Brake line repairs

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    - Remove self-grip pliers and tube fitting - D - from brakeline.

    - Slide brake line - B - against stop - A - in flaring tool.

    Note:

    Brake line must contact stop when hex socket heatscrews are tightened, otherwise flared head will notbe formed correctly.

    - Clamp brake line in flaring tool until it cannot be movedany more. Fold stop - A - up and tighten hex socket headscrews diagonally with angle screw driver - C - .

    Page 6 / 7Brake line repairs

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    - Turn spindle to stop in flaring tool.

    - Turn spindle back.

    - Loosen hex socket head screws diagonally.

    - Remove brake line from flaring tool, clean and checkbrake line and flared head.

    Briefly rinse part of brake line remaining in vehicle.

    - Connect brake filler/bleeder unit VAS 5234 , placebleeder container hose on flanged head of brake line andrun brake filler/bleeder unit VAS 5234 briefly until somebrake fluid runs through.

    - Blow out brake line to be inserted with compressed air.

    - Join brake lines with connecting piece - E - .

    - Assemble brake line.

    - Bleed braking system 47-4, Bleeding braking system

    Page 7 / 7Brake line repairs