Service

Workshop Manual
CC 2010 ➤
CC 2012 ➤
Passat CC 2009 ➤
Brake systems
Edition 12.2011

Service Department. Technical Information

 Service
List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups

Repair Group
00 - Technical data
45 - Anti-lock brake system
46 - Brakes - mechanism
47 - Brakes - hydraulics

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

K0059040820
 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Allocation of PR number - brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Technical data for brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Checking vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Checking vehicles with four-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Checking parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.1 Repair instructions for repair work on ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Vehicle diagnosis, testing and information system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Fitting location overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 Removing and installing control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Connecting brake lines to hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 Assembly overview - speed sensor on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 Removing and installing speed sensor on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.3 Assembly overview - speed sensor on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.4 Removing and installing speed sensor on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.5 Removing and installing ESP sensor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.6 Removing and installing steering angle sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.7 Removing and installing brake servo vacuum sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.1 Assembly overview - front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.1 Assembly overview - rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.1 Fitting location overview - parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.2 Removing and installing control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3.3 Removing and installing parking brake motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.1 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.2 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.3 Connecting brake pedal to brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1 Front brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.1 Assembly overview - front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.2 Removing and installing brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Contents i
 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

2 Rear brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

2.1 Assembly overview - rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.2 Removing and installing rear brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3 Brake servo and brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.1 Assembly overview - brake servo/brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.2 Removing and installing brake light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.3 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.4 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.1 Assembly overview - vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.2 Checking non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.3 Removing and installing brake servo pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.4 Checking brake servo vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
5 Brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.1 Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
6 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.1 General notes on brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.2 Pre-bleeding hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
6.3 Bleeding hydraulic system following standard procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.4 Subsequent bleeding of hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.5 Testing for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

ii Contents
 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

00 – Technical data
1 Identification
⇒ „1.1 Allocation of PR number - brakes“, page 1

1.1 Allocation of PR number - brakes

The type of brake system installed in the vehicle is indicated
amongst other things by the corresponding PR number on the
vehicle data sticker.
The vehicle data sticker can be found in the spare wheel well and
in the service booklet.
♦ Allocation ⇒ Electronic Parts Catalogue (ETKA) .
♦ The following table explains the PR numbers. These are im‐
portant for the brake caliper/brake disc and brake pads.

1.1.1 Front brakes

Engine PR No. Front brakes
1.4l - 118 kW 1LH / 1ZM FN3 (16”)
1.8l - 118 kW
2.0l - 147 kW
2.0l - 100, 103, 105 kW
TDI
2.0l -125 kW TDI
3.6l - 220 kW1) 1LK FNR-G (17”)
3.6l - 220 kW2) 1LA C60 (17”)
1) to 12.2010
2) as of 01.2011
Country specific brake for North America / Japan:
Engine PR No. Front brakes
2.0l - 147 kW 1ZG FN3 (16”)
3.6 l - 206 kW (front-
wheel drive)
3.6 l - 206 kW (four- 1LK FNR-G (17”)
wheel drive) 1)
3.6 l - 206 kW (four- 1LB C60 (17”)
wheel drive) 2)
1) to 12.2010
2) as of 01.2011

1.1.2 Rear brakes

Engine PR No. Rear brakes
1.4l - 118 kW 1KU / 1KW CII 38 (16")
1.8l - 118 kW
2.0l - 147 kW
2.0l - 100, 103, 105 kW
TDI
2.0l -125 kW TDI

Volkswagen Technical Site: http://vwts.ru http://vwts.info 1. Identification 1

 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

3.6l - 220 kW 2EA CII 41 (17")

Country specific brake for North America / Japan:
Engine PR No. Rear brakes
2.0l - 147 kW 1KU / 1KW CII 38 (16")
3.6 l - 206 kW (front-
wheel drive)
3.6 l - 206 kW (four- 2EA CII 41 (17")
wheel drive)

2 Rep. gr.00 - Technical data

 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

2 Technical data
⇒ „2.1 Technical data for brakes“, page 3

2.1 Technical data for brakes

⇒ „2.1.1 Brake master cylinder and brake servo“, page 3
⇒ „2.1.2 Front brakes“, page 3
⇒ „2.1.3 Rear brakes“, page 4

2.1.1 Brake master cylinder and brake servo

Brake master cylinder ∅ in mm 22.22
(low-output engine)
Brake master cylinder ∅ in mm 23.81
(high-output engine)
Brake servo (LHD) ∅ in inches 11
Brake servo (RHD) ∅ in inches 7/8

2.1.2 Front brakes

Front brakes FN3:
Item PR No. 1LH / 1ZG / 1ZM
1 Brake caliper FN3 (16”)
2 Brake lining, mm 14
thickness
Brake pad, wear mm 2
limit without
backplate
3 Brake disc ∅ in 312
mm
Brake disc, mm 25
thickness
Brake disc, mm 22
wear limit
4 Brake caliper, ∅ in 54
piston mm

Front brakes FNR-G:

Item PR No. 1LK
1 Brake caliper FNR-G (17”)
2 Brake lining, mm 14
thickness
Brake pad, wear mm 2
limit without
backplate
3 Brake disc ∅ in 345
mm
Brake disc, mm 30
thickness
Brake disc, mm 27
wear limit
4 Brake caliper, ∅ in 57
piston mm

2. Technical data 3
 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

Front brakes C60:

Item PR No. 1LA / 1LB
1 Brake caliper C60 (17”)
2 Brake lining, mm 13
thickness
Brake pad, wear mm 2
limit without
backplate
3 Brake disc ∅ in 340
mm
Brake disc, mm 30
thickness
Brake disc, mm 27
wear limit
4 Brake caliper, ∅ in 60
piston mm

2.1.3 Rear brakes

Rear brakes CII 38:
Item PR No. 1KU / 1KW
1 Brake caliper CII 38 (16")
2 Brake lining, mm 11
thickness
Brake pad, wear mm 2
limit without
backplate
3 Brake disc ∅ in 286
mm
Brake disc, mm 12
thickness
Brake disc, mm 10
wear limit
4 Brake caliper, ∅ in 38
piston mm

Rear brakes CII 41:

Item PR No. 2EA
1 Brake caliper CII 41 (17")
2 Brake lining, mm 11
thickness
Brake pad, wear mm 2
limit without
backplate
3 Brake disc ∅ in 310
mm
Brake disc, mm 22
thickness
Brake disc, mm 20
wear limit
4 Brake caliper, ∅ in 41
piston mm

4 Rep. gr.00 - Technical data

 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

3 Brake test
⇒ „3.1 General information“, page 5
⇒ „3.2 Checking vehicles with front-wheel drive“, page 5
⇒ „3.3 Checking vehicles with four-wheel drive“, page 5

3.1 General information

♦ The drive is provided by the roller dynamometer.
♦ For vehicles with a manual gearbox, ensure that the gear lever
is in neutral for the test. For vehicles with an automatic gear‐
box, ensure that the selector lever is in »N«.
♦ When conducting the test, observe the specifications provided
by the manufacturer of the test rig.

Note

The brake regulation systems do not function when ignition is off.

3.2 Checking vehicles with front-wheel drive

The brake test must be performed on a single-axle roller dyna‐
mometer.
The maximum test speed must not exceed 6 km/h.
The test rigs authorised by Volkswagen fulfil these requirements.

3.3 Checking vehicles with four-wheel drive

with Haldex coupling
⇒ „3.3.1 On a regulated roller dynamometer with contra-rotating
rollers for four-wheel drive vehicles“, page 5
⇒ „3.3.2 Without roller dynamometer for four-wheel drive vehi‐
cles“, page 6

3.3.1 On a regulated roller dynamometer with

contra-rotating rollers for four-wheel
drive vehicles
The brake test must be performed on a regulated single-axle roller
dynamometer with contra-rotating rollers for four-wheel drive ve‐
hicles.
„Contra-rotating“ means that the dynamometer rollers are driven
forwards on one side and backwards on the other side.
„Regulated“ means that the speed of the brake test stand rollers
is so controlled so that there is no difference in speed during the
brake test.
This prevents the transfer of a force through the stationary wheels
(not on the set of rollers) via the propshaft to the rotating wheels
on the rollers.
The forward rotating wheel is measured during the test, which
means two brake tests per axle must be performed.
The maximum test speed must not exceed 6 km/h.
The test rigs authorised by Volkswagen fulfil these requirements.

3. Brake test 5
 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

3.3.2 Without roller dynamometer for four-

wheel drive vehicles
If no test rig is available for four-wheel drive vehicles, the brake
test can also be carried out on a standard single-axle roller dy‐
namometer as follows:
– Drive vehicle forwards onto the rollers.
– Switch engine off and wait for 2 seconds.
– Carry out front brake test.
– Start engine and wait for approx. 5 seconds until sufficient
vacuum has been built up.
– Drive vehicle forwards until rear wheels are positioned on roll‐
ers.
– Switch engine off and wait for 2 seconds.
– Carry out rear brake test.
– Start engine and wait for approx. 5 seconds until sufficient
vacuum has been built up.

3.4 Checking parking brake

Electromechanical parking brake
⇒ „3.4.1 Checking vehicles with front-wheel drive:“, page 6
⇒ „3.4.2 Checking vehicles with four-wheel drive:“, page 7

3.4.1 Checking vehicles with front-wheel

drive:
Activate »TÜV mode«:
• Seat belt is fitted
• Rear axle on single-axle roller dynamometer
• Ignition remains switched on
• Auto-hold is switched off
• Front wheels must be stationary
• Rear wheels must rotate at constant speed between 2.5 and
9 km/h for at least 5 seconds.
Entering »TÜV mode« is indicated by the yellow electric parking
brake and handbrake fault warning lamp -K214- lighting up.

Note

In »TÜV mode«, the electromechanical parking brake does not

close fully when the button is first pressed.

The tension is increased gradually by actuating the electrome‐

chanical parking brake button -E538- four times in succession.
Actuating the electromechanical parking brake button -E538- a
fifth time releases the electromechanical parking brake.
End »TÜV mode«:
• Front wheels, speed over 0 km/h
• Rear wheels, speed lower than 2.5 km/h or over 9 km/h
• Ignition off.

6 Rep. gr.00 - Technical data

 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

3.4.2 Checking vehicles with four-wheel drive:

Activate »TÜV mode«:
• Seat belt is fitted
• Rear axle on single-axle roller dynamometer
• Engine is switched off and ignition is switched on
• Auto-hold is switched off
• Front wheels must be stationary
• Rear wheels must rotate at constant speed between 2.5 and
9 km/h for at least 5 seconds.
Entering »TÜV mode« is indicated by the yellow electric parking
brake and handbrake fault warning lamp -K214- lighting up.

Note

In »TÜV mode«, the electromechanical parking brake does not

close fully when the button is first pressed.

The tension is increased gradually by actuating the electrome‐

chanical parking brake button -E538- four times in succession.
Actuating the electromechanical parking brake button -E538- a
fifth time releases the electromechanical parking brake.
– Start engine and wait for approx. 5 seconds until sufficient
vacuum has been built up.
End »TÜV mode«:
• Front wheels, speed over 0 km/h
• Rear wheels, speed lower than 2.5 km/h or over 9 km/h
• Ignition off.

3. Brake test 7
 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

45 – Anti-lock brake system

1 General information
The ABS brake system is divided diagonally. The servo-assis‐
tance is effected pneumatically by the vacuum brake servo unit.
Vehicles with ABS are not fitted with a mechanical brake pressure
regulator. Specially matched software in the control unit regulates
the brake force distribution on the rear axle.
Faults in the ABS do not influence the brake system and servo
assistance. The conventional brake system remains functional
even without ABS. A change in braking behaviour is to be reck‐
oned with. After the ABS warning lamp comes on, the rear wheels
may lock prematurely during braking.
ABS layout in left-hand drive vehicle:
1 - Hydraulic unit and control unit
2 - Brake servo
The control unit and hydraulic are combined in a single compo‐
nent. Separation is not possible. Hydraulic pump must not be
separated from hydraulic unit either.

1.1 Repair instructions for repair work on

ABS
♦ Before carrying out repair work on the anti-lock brake system,
determine the cause of the fault as well as the control unit code
using „Guided Fault Finding“.
„Guided fault finding“ is carried out with the ⇒ Vehicle diagnostic
tester.
♦ Disconnect battery earth strap with ignition switched off.
♦ Before carrying out welding work with an electric welding unit,
note ⇒ General Information; Body Repairs, General Body Re‐
pairs .
♦ When working with brake fluid, observe the valid, relevant
safety precautions and notes ⇒ page 92 .
♦ After work for which the brake system had to be opened, bleed
the brake system with brake filling and bleeding unit -VAS
5234- ⇒ page 94 .
♦ During the final road test, ensure that a controlled brake test
is performed at least once (pulsations must be felt at the brake
pedal).
♦ Absolute cleanliness is required when working on the anti-lock
brake system. It is not permitted to use any products which
contain mineral oil, such as oils, greases etc.
♦ Thoroughly clean all unions and the adjacent areas before
loosening. Do not use aggressive cleaning agents such as
brake cleanser, petrol, thinners or similar.
♦ Place removed parts on a clean surface and cover.
♦ After separating the control unit/hydraulic unit, use the trans‐
port protection for the contact pins.
♦ If repairs cannot be carried out immediately, carefully cover or
seal open components. (Use sealing plugs from repair kit
1 H0 698 311 A).

8 Rep. gr.45 - Anti-lock brake system

 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

♦ Only use lint-free cloths.

♦ Only unpack replacement parts immediately prior to fitting.
♦ Only use genuine packed parts.
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ During painting operations, the electronic control unit can be
exposed to a maximum temperature of 95°C for only a short
period, and to a maximum of 85°C for longer periods (approx.
2 hours). Ensure that no brake fluid enters connectors.

1.2 Vehicle diagnosis, testing and informa‐

tion system
Connecting -Fahrzeugdiagnosetester- and selecting functions
Special tools and workshop equipment required
♦ Vehicle diagnosis, testing and information system -VAS 5051-
♦ Diagnosis cable -VAS 5051/1- or -VAS 5051/3-

WARNING

♦ During a road test, you must always secure testing and

measuring equipment on the back seat.
♦ These devices may be operated only by a passenger while
the vehicle is in motion.

– Connect connector of diagnosis cable -VAS 5051/1- or -

VAS 5051/3- to diagnostic connection.

1. General information 9
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Brake systems - Edition 12.2011

– Switch on tester -arrow-.

The tester is ready for operation when the selector buttons for the
operating modes appear on the screen.
– Switch on ignition.
– Touch Guided Fault Finding on screen.
– Select one after another:
♦ Brand
♦ Type
♦ Model year
♦ Body version
♦ Engine code
– Confirm data entered.
Wait until tester has read all control units in vehicle.
– Press Go to and select function „Function/component selec‐
tion“.
– Select „Running gear“ on display.
– Select „Brake systems“ on display.
– Select „01 Self-diagnosis capable system …“ shown on dis‐
play.
Either:
– Select „Anti-lock brake system …“ shown on display.
or:
– Select „Electromechanical parking brake“ on display.
– Select „Function“ shown on display.
All possible functions for the anti-lock brake system installed in
the vehicle will then be displayed.
– Select desired function on display.

10 Rep. gr.45 - Anti-lock brake system

 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

2 Fitting location overview

ABS/ESP:

1 - ABS control unit -J104-

❑ Location: on the hy‐
draulic unit on right in
engine compartment.
❑ Do not separate con‐
nector before success‐
fully completing self-di‐
agnosis. Switch ignition
off before separating
connector.
❑ Must not be separated
from ABS hydraulic unit
-N55-
❑ Removing and installing
⇒ page 14 .
2 - ABS hydraulic unit -N55-
❑ Location: on right in en‐
gine compartment.
The hydraulic unit consists of
the components:
❑ Brake pressure sender -
G201-
❑ ABS hydraulic pump -
V64-
❑ Valve block (contains in‐
let and outlet valves).
❑ ABS hydraulic pump -
V64- and valve block
must not be separated
from one another.
❑ Must not be separated
from ABS control unit -
J104-
❑ Removing and installing
⇒ page 14 .
3 - Brake pad warning lamp -K32-
❑ Location: in dash panel insert.
4 - ABS warning lamp -K47-
❑ Location: in dash panel insert.
5 - ESP and TCS warning lamp -K155-
❑ Location: in dash panel insert.
6 - Brake system warning lamp -K118-
❑ Location: in dash panel insert.
7 - Brake light switch -F-
❑ Location: on brake master cylinder.
❑ Removing and installing ⇒ page 73 .
8 - TCS and ESP button -E256-
❑ Location: in centre console.

2. Fitting location overview 11

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Brake systems - Edition 12.2011

9 - ESP sensor unit -G419- and control unit for electromechanical parking brake -J540-
❑ Location: under centre console.
❑ Combined lateral acceleration sender -G200- , yaw rate sender -G202- and longitudinal acceleration
sender -G251- .
❑ Installed in one housing together with control unit for electromechanical parking brake -J540-
❑ Removing and installing ⇒ page 23 .
10 - Diagnostic connection
❑ Location: Driver footwell cover.
11 - Steering angle sender -G85-
❑ Location: on steering column between steering wheel and steering column switch.
❑ Removing and installing ⇒ page 24 .
12 - Wheel bearing housing
13 - Front right/left speed sensor -G45- / -G47-
❑ Removing and installing ⇒ page 19 .
14 - Wheel hub with wheel bearing
❑ ABS sensor ring is installed in wheel bearing.
15 - Rear right/left speed sensor -G44- / -G46-
❑ Removing and installing ⇒ page 20 .
16 - Wheel bearing housing
Figure for front-wheel drive

17 - Wheel hub with wheel bearing

Figure for front-wheel drive
❑ ABS sensor ring is installed in wheel bearing.

12 Rep. gr.45 - Anti-lock brake system

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Brake systems - Edition 12.2011

3 Control unit and hydraulic unit

⇒ „3.1 Assembly overview“, page 13
⇒ „3.2 Removing and installing control unit and hydraulic unit“,
page 14
⇒ „3.3 Connecting brake lines to hydraulic unit“, page 17

3.1 Assembly overview

1 - ABS control unit -J104-

The control unit and hydraulic
unit cannot be separated.
❑ Removing and installing
⇒ page 14 .
2 - ABS hydraulic unit -N55-
The control unit and hydraulic
unit cannot be separated.
❑ Removing and installing
⇒ page 14 .
3 - Brake line
❑ To front right brake cali‐
per.
❑ Identification:
∅ 5.25 mm and union
nut with thread M10 x 1
❑ Marked on hydraulic
unit with „VR“
4 - Brake line
❑ To rear left brake cali‐
per.
❑ Identification: ∅
5.25 mm and union nut
with short thread M12 x
1
❑ Marked on hydraulic
unit with „HL“
5 - Brake line
❑ To rear right brake cali‐
per.
❑ Identification:
∅ 5.25 mm and union
nut with thread M10 x 1
❑ Marked on hydraulic unit with „HR“
6 - Brake line
❑ To front left brake caliper.
❑ Identification: ∅ 5.25 mm and union nut with short thread M12 x 1
❑ Marked on hydraulic unit with „VL“
7 - Brake line
❑ From primary piston circuit of brake master cylinder to hydraulic unit.
❑ Identification: ∅ 8.5 mm or ∅ 6 mm and union nut with long thread M12x1
❑ Marked on hydraulic unit with „HZ1“

Volkswagen Technical Site: http://vwts.ru http://vwts.info 3. Control unit and hydraulic unit 13
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Brake systems - Edition 12.2011

8 - Brake line
❑ From secondary piston circuit of brake master cylinder to hydraulic unit.
❑ Identification: ∅ 8.5 mm or ∅ 6 mm and union nut with long thread M12x1
❑ Marked on hydraulic unit with „HZ2“
9 - Heat shield
Allocation ⇒ Electronic Parts Catalogue (ETKA) .

10 - Torx socket head bolt, 12 Nm

11 - Brake servo
❑ A vacuum sender is fitted in vehicles with HBV ⇒ page 24 .
❑ Removing and installing ⇒ page 75 .
12 - Bracket
13 - Hexagon nut, 20 Nm
14 - Rubber damper
15 - Torx socket head bolt, 10 Nm
16 - Bracket

3.2 Removing and installing control unit and hydraulic unit

Special tools and workshop

equipment required
♦ Torque wrench -V.A.G
1331-
♦ Torque wrench -V.A.G
1410-
♦ Brake pedal depressor -

14 Rep. gr.45 - Anti-lock brake system

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Brake systems - Edition 12.2011

V.A.G 1869/2-

Sealing plugs repair kit, Part No. 1H0 698 311 A

1 - Transport protection for contact pins (foam)
2 - Sealing plug M10
3 - Sealing plug M12
Removing:
Location:
The control unit is bolted to the hydraulic unit and is located on
right in the engine compartment.

WARNING

Do not bend the brake lines in the area of the hydraulic unit!

– Read out and note the existing control unit code.

– Note or request radio code on vehicles with coded radio if
necessary.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and reconnecting battery.
– Remove engine cover panel.
1.8l TSI engine:
– Remove air pipe ⇒ Rep. gr. 21 ; Turbocharger .
– Seal off turbocharger using engine bung set -VAS 6122-.
2.0 l diesel engine with diesel particulate filter:
– Unscrew exhaust gas pressure sensor 1 -G450- and retainer,
then separate electrical connectors.
– Unbolt heat shield for right drive shaft.
– Unbolt double clamp between front exhaust pipe with diesel
particulate filter and front silencer.
– Unbolt particulate filter, lower filter and carefully place it to side
⇒ Rep. gr. 26 ; Cleansing exhaust emissions; Assembly
overview - cleansing exhaust emissions .
6-cylinder petrol engine:
– Disconnect connectors for knock sensor and for valves in vac‐
uum hoses from rear of intake manifold. Unclip wiring harness
from retainers on coolant pipe and lay aside.
– Pull off vacuum hoses on back of intake manifold, remove from
retainers and completely lay aside.
– Disconnect rear coolant pipe on side and back of engine.
– Clamp off coolant hose on expansion tank with hose clamps
to 25 mm Ø -3094- .
– Now pull coolant hose off coolant expansion tank and place
as far as possible to side along with coolant pipe.
Continuation for all models:
– In vehicles with heat shield, remove heat shield.

3. Control unit and hydraulic unit 15

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– Press red locking slide to rear in direction of -arrow-.

– Release connector from control unit in direction of -arrow- and

pull off.
– Apply brake pedal depressor -V.A.G 1869/2- .
– Connect bleeder bottle hose to front left brake caliper bleeder
valve and rear left brake caliper bleeder valve and open bleed‐
er valves.
– Depress brake pedal at least 60 mm using brake pedal de‐
pressor -V.A.G 1869/2- .
– Close front left and rear left bleeder valve.
– Do not remove brake pedal depressor -V.A.G 1869/2- .
– Place sufficient lint-free cloths under the control unit and hy‐
draulic unit.
Ensure no brake fluid gets onto contacts.
– First identify both brake lines from brake master cylinder and
unscrew from hydraulic unit.
– Immediately seal brake lines and threaded holes with plugs
from repair kit Part No. 1H0 698 311 A.
– Mark, unscrew and seal remaining brake lines (brake cali‐
pers).
Vehicles with diesel particulate filter:
– Completely remove front right brake line.
Continuation for all models:

– Pull hydraulic unit together with control unit upwards out of

dampers -arrow-.
Installing:

Note

♦ Remove sealing plugs from new hydraulic unit only when the
corresponding brake line is to be fitted.
♦ If sealing plugs are removed too early from the hydraulic unit,
brake fluid can escape, and it can then no longer be guaran‐
teed that the unit can be sufficiently filled and bled.
♦ When installing the hydraulic unit, ensure that the rubber
dampers are not pressed out of bracket.

– Install in reverse order.

16 Rep. gr.45 - Anti-lock brake system

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Brake systems - Edition 12.2011

Tightening sequence of brake lines:

– Remove brake pedal depressor -V.A.G 1869/2- .
– Bleed brake system ⇒ page 94 .
– Code radio.
– Code control unit -J104- with ⇒ Vehicle diagnostic tester in
”Guided fault finding”.
To do this, carry out basic setting of the steering angle sender -
G85- , the lateral acceleration sender -G200- , the longitudinal
acceleration sender -G251- and the brake pressure sender -
G201- .
Specified torques:
Hexagon bolt of hydraulic unit to bracket 10 Nm
Brake lines to ABS unit:
Brake lines 1 to 4 (brake calipers) 14 Nm
Brake lines 5 and 6 (brake master cylinder)
∅ 8.5 mm 17 Nm
∅ 6 mm 14 Nm

3.3 Connecting brake lines to hydraulic unit

On tandem brake master cylinder:
A - Primary piston circuit of brake master cylinder to hydraulic unit.
- Identification: ∅ 8.5 mm or ∅ 6 mm and union nut with long
thread M12 x 1.
B - Secondary piston circuit of brake master cylinder to hydraulic
unit.
- Identification: ∅ 8.5 mm or ∅ 6 mm and union nut with long
thread M12 x 1.
1 - From hydraulic unit to front left brake caliper.
3 - From hydraulic unit to rear left brake caliper.
4 - From hydraulic unit to rear right brake caliper.

3. Control unit and hydraulic unit 17

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On hydraulic unit:
1 - From hydraulic unit to front left brake caliper.
- Identification: ∅ 5.25 mm and union nut with short thread M12
x1
2 - From hydraulic unit to rear right brake caliper.
- Identification: ∅ 5.25 mm and union nut with thread M10 x 1
3 - From hydraulic unit to rear left brake caliper.
- Identification: ∅ 5.25 mm and union nut with short thread M12
x1
4 - From hydraulic unit to front right brake caliper.
- Identification: ∅ 5.25 mm and union nut with thread M10 x 1
5 - From hydraulic unit to primary piston circuit of brake master
cylinder.
- Identification: ∅ 8.5 mm or ∅ 6 mm and union nut with long
thread M12x1
6 - From hydraulic unit to secondary piston circuit of brake master
cylinder.
- Identification: ∅ 8.5 mm or ∅ 6 mm and union nut with long
thread M12x1

18 Rep. gr.45 - Anti-lock brake system

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Brake systems - Edition 12.2011

4 Sensors
⇒ „4.1 Assembly overview - speed sensor on front axle“,
page 19
⇒ „4.2 Removing and installing speed sensor on front axle“, page
20
⇒ „4.3 Assembly overview - speed sensor on rear axle“,
page 20
⇒ „4.4 Removing and installing speed sensor on rear axle“, page
22
⇒ „4.5 Removing and installing ESP sensor unit“, page 23
⇒ „4.6 Removing and installing steering angle sender“,
page 24
⇒ „4.7 Removing and installing brake servo vacuum sender“,
page 24

4.1 Assembly overview - speed sensor on front axle

1 - ABS speed sensor

❑ Before inserting sensor,
clean hole inner surface
and coat with high-tem‐
perature paste
G 052 112 A3.
❑ Removing and installing
⇒ page 20 .
2 - Hexagon socket head bolt,
8 Nm
3 - Wheel hub with wheel bear‐
ing
❑ ABS sensor ring is in‐
stalled in wheel bearing.
4 - Drive shaft

4. Sensors 19
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4.2 Removing and installing speed sensor

on front axle
Removing
– Raise vehicle.
– Separate connector -1- from speed sensor wire and from
speed sensor.
– Remove bolt -2- from wheel bearing housing.
– Pull ABS speed sensor out of wheel bearing housing.
Installing
– Before inserting speed sensor, clean hole inner surface and
coat speed sensor all-round with high-temperature paste
G 052 112 A3.
– Insert speed sensor into hole in wheel bearing housing and
tighten bolt to 8 Nm.
– Connect speed sensor to speed sensor wire.

4.3 Assembly overview - speed sensor on

rear axle
⇒ „4.3.1 Assembly overview - front-wheel drive“, page 21
⇒ „4.3.2 Assembly overview - four-wheel drive“, page 22

20 Rep. gr.45 - Anti-lock brake system

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Brake systems - Edition 12.2011

4.3.1 Assembly overview - front-wheel drive

1 - ABS speed sensor

❑ Before inserting sensor,
clean hole inner surface
and coat with high-tem‐
perature paste
G 052 112 A3.
❑ Removing and installing
⇒ page 22 .
2 - Hexagon socket head bolt,
8 Nm
3 - Wheel hub with wheel bear‐
ing
❑ ABS sensor ring is in‐
stalled in wheel bearing.

4. Sensors 21
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4.3.2 Assembly overview - four-wheel drive

1 - ABS speed sensor

❑ Before inserting sensor,
clean hole inner surface
and coat with high-tem‐
perature paste
G 052 112 A3.
❑ Removing and installing
⇒ page 23 .
2 - Hexagon socket head bolt,
8 Nm
3 - Wheel hub with wheel bear‐
ing
❑ ABS sensor ring is in‐
stalled in wheel bearing.

4.4 Removing and installing speed sensor

on rear axle
⇒ „4.4.1 Front-wheel drive“, page 22
⇒ „4.4.2 Four-wheel drive“, page 23

4.4.1 Front-wheel drive

Removing:
– Raise vehicle.

22 Rep. gr.45 - Anti-lock brake system

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– Separate connector -1- from speed sensor wire and from

speed sensor.
– Remove bolt -2- from wheel bearing housing.
– Pull ABS speed sensor out of wheel bearing housing.
Installing:
– Before inserting speed sensor, clean hole inner surface and
coat speed sensor all-round with high-temperature paste
G 052 112 A3.
– Insert speed sensor into hole in wheel bearing housing and
tighten bolt to 8 Nm.
– Connect speed sensor to speed sensor wire.

4.4.2 Four-wheel drive

Removing:
– Raise vehicle.
– Separate connector -1- from speed sensor wire and from
speed sensor.
– Remove bolt -2- from wheel bearing housing.
– Pull ABS speed sensor out of wheel bearing housing.
Installing:
– Before inserting speed sensor, clean hole inner surface and
coat speed sensor all-round with high-temperature paste
G 052 112 A3.
– Insert speed sensor into hole in wheel bearing housing and
tighten bolt to 8 Nm.
– Connect speed sensor to speed sensor wire.

4.5 Removing and installing ESP sensor

unit
The lateral acceleration sender -G200- , the yaw rate sender -
G202- and the longitudinal acceleration sender -G251- are in‐
stalled in a housing together with the control unit for electrome‐
chanical parking brake -J540- ; this is located below the centre
console.
After the ESP sensor unit -G419- has been replaced together with
the control unit for electromechanical parking brake -J540- , it is
necessary to code the ABS control unit -J104- and to carry out a
basic setting of the „brake system“ (electromechanical parking
brake).

WARNING

Severe shocks (e.g. dropping, impact) may destroy the ESP

sensor unit -G419- . The ESP sensor unit -G419- may not then
be used any further.

Removing:
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
sole .

4. Sensors 23
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– Pull connector -1- off ESP sensor unit -G419- .

– Remove the three securing nuts -arrows-.
– Remove ESP sensor unit -G419- .
Installing:
– Install in reverse order.
When installing the ESP sensor unit -G419- , make sure it is cor‐
rectly seated in its bracket and is free of stress.

Note

Do not use the securing nuts to forcibly position ESP sensor unit
-G419- .

– Tighten securing nuts to 9 Nm.

– Code control unit -J104- with ⇒ Vehicle diagnostic tester in
”Guided fault finding”.
To do this, carry out basic setting of steering angle sender -G85- ,
lateral acceleration sender -G200- , brake pressure sender -
G201- and longitudinal acceleration sender -G251- .
– Carry out basic setting of „brake system“ (electromechanical
parking brake).
Connecting ⇒ Vehicle diagnostic tester and selecting functions
⇒ page 9 .

4.6 Removing and installing steering angle

sender
The steering angle sender -G85- is located between the steering
wheel and steering column switch.
Removing and installing:
⇒ Electrical system; Rep. gr. 94 ; Steering column switch module;
Assembly overview - steering column switch module .
– Then perform basic setting of steering angle sender -G85- .
Connecting ⇒ Vehicle diagnostic tester and selecting functions
⇒ page 9 .

4.7 Removing and installing brake servo

vacuum sender
Removing:
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery;
Removing and installing battery .
The battery is installed in the luggage compartment on vehicles
with a 6-cylinder petrol engine and therefore only the air filter
housing must be removed.
– Remove battery tray.

24 Rep. gr.45 - Anti-lock brake system

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Brake systems - Edition 12.2011

– Disconnect connector -1- from brake servo vacuum sender -

G483- -2-.
– Insert screwdriver into circlip groove between stop and one
end of circlip.

– Now press circlip -1- out of groove until brake servo vacuum
sender -G483- -2- can be pulled out of brake servo.
Installing:
– Install in reverse order.

4. Sensors 25
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46 – Brakes - mechanism
1 Front brakes

1.1 Assembly overview - front brakes

⇒ „1.1.1 Assembly overview - front brakes FN 3“, page 26
⇒ „1.1.2 Assembly overview - front brakes FNR-G“, page 28
⇒ „1.1.3 Assembly overview- front brakes C60“, page 29

1.1.1 Assembly overview - front brakes FN 3

Note

♦ After every brake pad change, depress brake pedal firmly sev‐
eral times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
♦ Use the brake filling and bleeding equipment -VAS 5234- to
draw off brake fluid from the brake fluid reservoir.
♦ Before removing a brake caliper or disconnecting a brake
hose, fit brake pedal depressor -V.A.G 1869/2- (when doing
this, release pressure in system).

26 Rep. gr.46 - Brakes - mechanism

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1 - Splash plate
2 - Torx bolt, 12 Nm
3 - Brake disc
❑ Ventilated, ∅ 312 mm
❑ Thickness: 25 mm
❑ Wear limit: 22 mm.
❑ Always renew on both
sides of an axle.
❑ Remove brake caliper
and brake carrier prior to
removing.
4 - Torx bolt, 4 Nm
5 - Brake carrier
❑ Bolt to wheel bearing
housing.
6 - Retaining spring
❑ Insert into both holes in
brake caliper.
7 - Ribbed bolt, 200 Nm
❑ Clean if reused.
8 - Brake pads
❑ Thickness: 14 mm not
including backplate.
❑ With brake pad wear in‐
dicator (front left)
❑ When wear reaches a
predetermined limit (ap‐
prox 4 mm excluding
backplate), the warning
lamp in the dash panel
insert comes on.
❑ Wear limit: 2 mm not in‐
cluding backplate.
❑ Checking thickness ⇒ Maintenance ; Booklet ; Front and rear brake discs and pads/linings: Checking
condition of discs and thickness of pads/linings .
❑ Always renew on both sides of an axle.
❑ Removing and installing ⇒ page 31 .
9 - Brake caliper
❑ Do not disconnect brake hose when changing pads.
❑ Removing and installing ⇒ page 39 .
❑ Repairing ⇒ page 58 .
10 - Guide pin, 30 Nm
11 - Cover cap
❑ Remove
12 - Brake hose with banjo union and banjo bolt, 35 Nm
13 - Bolt, 8 Nm
14 - Bracket
15 - Retaining clip

1. Front brakes 27
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1.1.2 Assembly overview - front brakes FNR-

G

Note

♦ After every brake pad change, depress brake pedal firmly sev‐
eral times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
♦ Use the brake filling and bleeding equipment -VAS 5234- to
draw off brake fluid from the brake fluid reservoir.
♦ Before removing a brake caliper or disconnecting a brake
hose, fit brake pedal depressor -V.A.G 1869/2- (when doing
this, release pressure in system).

1 - Splash plate
2 - Torx bolt, 12 Nm
3 - Brake disc
❑ Ventilated, ∅ 345 mm
❑ Thickness: 30 mm
❑ Wear limit: 27 mm.
❑ Always renew on both
sides of an axle.
❑ Unscrew brake caliper
prior to removing.
4 - Torx bolt, 4 Nm
5 - Brake carrier
❑ Bolt to wheel bearing
housing.
6 - Retaining spring
❑ Insert into brake pad re‐
taining spring and press
under brake carrier.
7 - Ribbed bolt, 190 Nm
❑ Clean if reused.
8 - Brake pads
❑ Thickness: 14 mm not
including backplate.
❑ With break pad wear in‐
dicator.
❑ When wear reaches a
predetermined limit (ap‐
prox. 4 mm) the warning
lamp in the dash panel
insert comes on.
❑ Wear limit: 2 mm not in‐
cluding backplate.
❑ Checking thickness ⇒ Maintenance ; Booklet ; Front and rear brake discs and pads/linings: Checking
condition of discs and thickness of pads/linings .
❑ Always renew on both sides of an axle.
❑ Removing and installing ⇒ page 33 .
9 - Brake caliper
❑ Do not disconnect brake hose when changing brake pads.

28 Rep. gr.46 - Brakes - mechanism

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Brake systems - Edition 12.2011
❑ Must not be unscrewed from one another.
❑ Removing and installing ⇒ page 41 .
❑ Repairing ⇒ page 59 .
10 - Guide pin, 30 Nm
11 - Cover cap
❑ Remove
12 - Washer
13 - Balance weight
14 - Bolt, 10 Nm
15 - Dust cap
16 - Bracket
17 - Bolt, 15 Nm
18 - Brake line, 14 Nm
19 - Brake hose
20 - Hexagon socket head bolt, 8 Nm
21 - Bracket
22 - Spring clip

1.1.3 Assembly overview- front brakes C60

Note

♦ After every brake pad change, depress brake pedal firmly sev‐
eral times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
♦ Use the brake filling and bleeding equipment -VAS 5234- to
draw off brake fluid from the brake fluid reservoir.
♦ Before removing a brake caliper or disconnecting a brake
hose, fit brake pedal depressor -V.A.G 1869/2- (when doing
this, release pressure in system).

1. Front brakes 29
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Brake systems - Edition 12.2011

1 - Splash plate
2 - Torx bolt, 12 Nm
3 - Brake disc
❑ Ventilated, ∅ 340 mm
❑ Thickness: 30 mm
❑ Wear limit: 27 mm.
❑ Always renew on both
sides of an axle.
❑ Remove brake caliper
and brake carrier prior to
removing.
4 - Torx bolt, 4 Nm
5 - Brake carrier
❑ Bolt to wheel bearing
housing.
6 - Brake pads
❑ Thickness: 13 mm not
including backplate.
❑ With brake pad wear in‐
dicator
❑ When wear reaches a
predetermined limit (ap‐
prox. 4 mm) the warning
lamp in the dash panel
insert comes on.
❑ Wear limit: 2 mm not in‐
cluding backplate.
❑ Checking thickness
⇒ Maintenance ; Book‐
let ; Front and rear
brake discs and pads/
linings: Checking condi‐
tion of discs and thick‐
ness of pads/linings .
❑ Always renew on both sides of an axle.
❑ Removing and installing ⇒ page 36 .
7 - Brake caliper
❑ Do not disconnect brake hose when changing pads.
❑ Removing and installing ⇒ page 42 .
❑ Repairing ⇒ page 59 .
8 - Self-locking hexagon bolt, 35 Nm
❑ Renew.
9 - Ribbed bolt, 200 Nm
❑ Clean if reused.
10 - Wheel bearing housing
❑ With bolted brake carrier.
11 - Brake hose with banjo union and banjo bolt, 35 Nm
12 - Retaining clip
13 - Bracket
14 - Bolt, 8 Nm

30 Rep. gr.46 - Brakes - mechanism

 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

1.2 Removing and installing brake pads/lin‐

ings
⇒ „1.2.1 Removing and installing brake pads, front brakes FN 3“,
page 31
⇒ „1.2.2 Removing and installing brake pads, front brakes FNR-
G“, page 33
⇒ „1.2.3 Removing and installing brake pads, front brakes C60“,
page 36

1.2.1 Removing and installing brake pads,

front brakes FN 3
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-

♦ Piston resetting appliance -T10145-

Removing:
Mark brake pads/linings when removing if they are to be reused.
Fit in same position when installing, or braking will be uneven.
– Remove wheels.
– Lever brake pad retaining spring out from brake caliper
-arrow- with a screwdriver and remove.

1. Front brakes 31
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Brake systems - Edition 12.2011

– Disconnect connector -1- for brake pad wear indicator.

– Remove cover caps -arrows-.

– Unscrew both guide pins -arrows- and remove from brake cal‐
iper.
– Remove brake caliper and secure with wire so that weight of
brake caliper does not strain or damage brake hose.
– Take brake pad out of brake caliper or from brake carrier.
Cleaning:

WARNING

Do not blow out brake system with compressed air; the result‐
ing dust constitutes a health hazard!

– Thoroughly clean brake carrier and contact surfaces for brake

pads and remove corrosion.
– Clean brake caliper.
Use only methylated spirits for cleaning the brake caliper housing.
Installing:
Before pressing piston back into cylinder with piston resetting tool,
draw off brake fluid from brake fluid reservoir. Otherwise, partic‐
ularly if reservoir has been topped up, fluid will overflow and cause
damage.

32 Rep. gr.46 - Brakes - mechanism

 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

– Press piston back.

– Fit outer brake pad to brake carrier.
– Insert inner brake pad with retaining spring into brake caliper
(piston).

– Bolt brake caliper to brake carrier with both guide pins.

– Fit both cover caps.
– Insert retaining spring into brake caliper.
– Reconnect connector for brake pad wear indicator.
– Fit wheels.
Specified torque for wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Wheels, tyres; Specified torque for wheel bolts .

Note

♦ After every brake pad change, depress brake pedal firmly sev‐
eral times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
♦ Check brake fluid level after changing brake pads.

Specified torque:
Guide pin to brake carrier 30 Nm

1.2.2 Removing and installing brake pads,

front brakes FNR-G
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-

1. Front brakes 33
 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

♦ Piston resetting appliance -T 10145-

Removing:
Mark brake pads/linings when removing if they are to be reused.
Fit in same position when installing, or braking will be uneven.
– Remove wheels.
– Lever brake caliper retaining spring out of brake pad retaining
spring using a screwdriver. To do this, position screwdriver
between the two retaining springs -enlargement-.
– Firmly hold brake caliper retaining spring with a cloth to pre‐
vent loss.

– Disconnect connector -1- for brake pad wear indicator.

– Remove cover caps -arrows-.

34 Rep. gr.46 - Brakes - mechanism

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Brake systems - Edition 12.2011

– Unscrew both guide pins -arrows- and remove from brake cal‐
iper.
– Remove brake caliper and secure with wire so that weight of
brake caliper does not strain or damage brake hose.
– Take brake pads out of brake caliper.
Cleaning:

WARNING

Do not blow out brake system with compressed air; the result‐
ing dust constitutes a health hazard!

– Thoroughly clean brake carrier and contact surfaces for brake

pads and remove corrosion.
– Clean brake caliper.
Use only methylated spirits for cleaning the brake caliper housing.
Installing:
Before pressing piston back into cylinder with piston resetting tool,
draw off brake fluid from brake fluid reservoir. Otherwise, partic‐
ularly if reservoir has been topped up, fluid will overflow and cause
damage.

– Press piston back.

– Insert inner brake pad with retaining spring into brake caliper
(piston).

1. Front brakes 35
 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

– Insert outer brake pad -2- with retaining spring in caliper.

– Fit brake caliper with brake pads onto brake carrier.

– Bolt brake caliper to brake carrier with both guide pins.

– Fit both cover caps.
– Insert brake caliper retaining spring into brake pad retaining
spring and press under brake carrier.
– Reconnect connector for brake pad wear indicator.
– Fit wheels.
Specified torque for wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Wheels, tyres; Specified torque for wheel bolts .

Note

♦ After every brake pad change, depress brake pedal firmly sev‐
eral times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
♦ Check brake fluid level after changing brake pads.

Specified torque:
Guide pin to brake carrier 30 Nm

1.2.3 Removing and installing brake pads,

front brakes C60
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-

36 Rep. gr.46 - Brakes - mechanism

 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

♦ Piston resetting appliance -T 10145-

Removing:
Mark brake pads/linings when removing if they are to be reused.
Fit in same position when installing, or braking will be uneven.
– Remove wheels.
– Disconnect connector -1- for brake pad wear indicator.

– Unscrew both securing bolts from brake caliper; to do this,

counterhold on guide pin.

1. Front brakes 37
 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

– Remove brake caliper -1- and secure with wire so that weight
of brake caliper does not strain or damage brake hose.
– Remove brake pads -2 and 3- from brake support plate -4-.
Cleaning:

WARNING

Do not blow out brake system with compressed air; the result‐
ing dust constitutes a health hazard!

– Thoroughly clean brake carrier and contact surfaces for brake

pads and remove corrosion.
– Clean brake caliper.
Use only methylated spirits for cleaning the brake caliper housing.
Installing:
Before pressing piston back into cylinder with piston resetting tool,
draw off brake fluid from brake fluid reservoir. Otherwise, partic‐
ularly if reservoir has been topped up, fluid will overflow and cause
damage.

– Press piston back.

– Place the brake pads -2- together with retaining springs -1- in
the recess of the brake support plate -3-.
– Carefully place the brake caliper on the brake support plate.

38 Rep. gr.46 - Brakes - mechanism

 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

– Secure brake caliper to brake support plate with new self-

locking bolts, counterholding with the guide bolts.

– Connect brake pad wear indicator connector -1-.

– Fit wheels.
Specified torque for wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Wheels, tyres; Specified torque for wheel bolts .

Note

♦ After every brake pad change, depress brake pedal firmly sev‐
eral times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
♦ Check brake fluid level after changing brake pads.

Specified torque:
Hexagon bolt, brake caliper to brake carrier 35 Nm
♦ Use new bolts!

1.3 Removing and installing brake caliper

⇒ „1.3.1 Removing and installing brake caliper FN3“, page 39
⇒ „1.3.2 Removing and installing brake caliper FNR-G“,
page 41
⇒ „1.3.3 Removing and installing brake caliper C60“, page 42

1.3.1 Removing and installing brake caliper

FN3
Special tools and workshop equipment required

1. Front brakes 39
 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

♦ Torque wrench -V.A.G 1331-

♦ Brake pedal depressor -V.A.G 1869/2-

This procedure applies only to exchanging or the following repair

work on the brake caliper.
Removing:
– Remove wheels.
– Lever brake pad retaining spring out from brake caliper with a
screwdriver and remove.
– Separate connector for brake pad wear indicator.
– Connect bleeder bottle hose to brake caliper bleeder valve and
open bleeder valve.
– Apply brake pedal actuator -V.A.G 1869/2- .
– Close bleeder valve and remove bleeder bottle.
– Disconnect brake hose.
– Pull both caps out of bearing bushes of brake caliper.
– Loosen both guide pins and remove from brake caliper.
– Pull brake caliper off brake carrier.
– Remove brake pads from brake caliper.
Installing:
• Piston is pressed back.
• Outer brake pad is seated on brake carrier.
– Insert inner brake pad with retaining spring into brake caliper
(piston).
– Bolt brake caliper to brake carrier with both guide pins.
– Fit both cover caps.
– Bolt brake hose to brake caliper.
– Remove brake pedal actuator -V.A.G 1869/2- .

40 Rep. gr.46 - Brakes - mechanism

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Brake systems - Edition 12.2011

– Insert retaining spring into brake caliper.

– Reconnect connector for brake pad wear indicator.
– Bleed brake system ⇒ page 94 .
– Fit wheels.
Specified torque for wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Wheels, tyres; Specified torque for wheel bolts .

Note

♦ Firmly depress brake pedal several times with vehicle station‐

ary so that the brake pads are properly seated in their normal
operating position.
♦ Check brake fluid level.

Specified torques:
Guide pin to brake carrier 30 Nm
Brake hose to brake caliper 35 Nm

1.3.2 Removing and installing brake caliper

FNR-G
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-

♦ Brake pedal depressor -V.A.G 1869/2-

This procedure applies only to exchanging or the following repair

work on the brake caliper.
Removing:
– Remove wheels.
– Lever brake caliper retaining spring out of brake pad retaining
spring using a screwdriver. To do this, position screwdriver
between both retaining springs.

1. Front brakes 41
 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

– Firmly hold brake caliper retaining spring with a cloth to pre‐

vent loss.
– Separate connector for brake pad wear indicator.
– Connect bleeder bottle hose to brake caliper bleeder valve and
open bleeder valve.
– Apply brake pedal actuator -V.A.G 1869/2- .
– Close bleeder valve and remove bleeder bottle.
– Disconnect brake hose.
– Pull both caps out of bearing bushes of brake caliper.
– Loosen both guide pins and remove from brake caliper.
– Pull brake caliper off brake carrier.
– Remove brake pads from brake caliper.
Installing:
• Piston is pressed back.
– Insert inner brake pad with retaining spring into brake caliper
(piston).
– Insert outer brake pad with retaining spring in brake caliper.
– Fit brake caliper with brake pads onto brake carrier.
– Bolt brake caliper to brake carrier with both guide pins.
– Fit both cover caps.
– Connect brake hose to brake line from brake caliper.
– Remove brake pedal actuator -V.A.G 1869/2- .
– Insert brake caliper retaining spring into brake pad retaining
spring and press under brake carrier.
– Reconnect connector for brake pad wear indicator.
– Bleed brake system ⇒ page 94 .
– Fit wheels.
Specified torque for wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Wheels, tyres; Specified torque for wheel bolts .

Note

♦ Firmly depress brake pedal several times with vehicle station‐

ary so that the brake pads are properly seated in their normal
operating position.
♦ Check brake fluid level.

Specified torques:
Guide pin to brake carrier 30 Nm
Brake hose to brake line 14 Nm

1.3.3 Removing and installing brake caliper

C60
Special tools and workshop equipment required

42 Rep. gr.46 - Brakes - mechanism

 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

♦ Torque wrench -V.A.G 1331-

♦ Brake pedal depressor -V.A.G 1869/2-

This procedure applies only to exchanging or the following repair

work on the brake caliper.
Removing:
– Remove wheels.
– Disconnect connector for brake pad wear indicator.
– Connect bleeder bottle hose to brake caliper bleeder valve and
open bleeder valve.
– Apply brake pedal depressor -V.A.G 1869/2- .
– Close bleed valve and remove bleed bottle.
– Unscrew brake hose.
– Unscrew both securing bolts from brake caliper; to do this,
counterhold on guide pin.
– Pull brake caliper from brake support plate.
Installing:
• Piston is pressed back.
• The two brake pads are seated in the retaining springs on the
brake support plate.
– Carefully place the brake caliper on the brake support plate.
– Secure brake caliper to brake support plate with new self-
locking bolts, counterholding with the guide bolts.
– Screw brake hose onto brake caliper.
– Remove brake pedal depressor -V.A.G 1869/2- .
– Connect brake pad wear indicator connector.
– Bleed brake system.
– Fit wheels.

1. Front brakes 43
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Brake systems - Edition 12.2011

Specified torque for wheel bolts ⇒ Running gear, axles, steering;

Rep. gr. 44 ; Wheels, tyres; Specified torque for wheel bolts .

Note

♦ Firmly depress brake pedal several times with vehicle station‐

ary so that the brake pads are properly seated in their normal
operating position.
♦ Check brake fluid level.

Specified torque:
Hexagon bolt, brake caliper to brake carrier 35 Nm
♦ Use new bolts!

Brake hose to brake caliper 35 Nm

44 Rep. gr.46 - Brakes - mechanism

 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

2 Rear brakes
⇒ „2.1 Assembly overview - rear brakes“, page 45
⇒ „2.2 Removing and installing brake pads/linings“, page 46
⇒ „2.3 Removing and installing brake caliper“, page 49

2.1 Assembly overview - rear brakes

Assembly overview - rear brakes CII 38 and CII 41

Note

♦ Use the brake filling and bleeding equipment -VAS 5234- to

draw off brake fluid from the brake fluid reservoir.
♦ Before removing a brake caliper or disconnecting a brake
hose, fit brake pedal depressor -V.A.G 1869/2- (when doing
this, release pressure in system).

1 - Splash plate
❑ Allocation ⇒ Electronic
parts catalogue (ETKA)
2 - Brake disc
❑ 16 inch: ∅ 286 mm
❑ 17 inch: ∅ 310 mm
❑ Thickness 16 inch: 12
mm
❑ Thickness 17 inch: 22
mm
❑ Wear limit 16 inch: 10
mm
❑ Wear limit 17 inch: 20
mm
❑ When worn, renew on
both sides of axle.
❑ Remove brake caliper
and brake carrier prior to
removing.
3 - Torx socket head bolt, 4 Nm
4 - Multi-point socket head bolt,
90 Nm and turn 90° further
❑ Always renew after re‐
moving.
5 - Brake carrier with guide pin
(s) and protective cap
❑ Supplied as genuine
part, assembled with
sufficient grease on
guide pins.
❑ If protective caps or
guide pins are dam‐
aged, install repair kit.
Use lubricant sachet
supplied to lubricate guide pins.
6 - Pad retainer
❑ Always renew when changing pads.

2. Rear brakes 45
 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

7 - Brake pad
❑ Thickness: 11 mm not including backplate.
❑ Wear limit: 2 mm not including backplate.
❑ Checking thickness ⇒ Maintenance ; Booklet ; Front and rear brake discs and pads/linings: Checking
condition of discs and thickness of pads/linings .
❑ Always renew on both sides of an axle.
❑ Removing and installing ⇒ page 46 .
8 - Brake pad
❑ Thickness: 11 mm not including backplate.
❑ Wear limit: 2 mm not including backplate.
❑ Checking thickness ⇒ Maintenance ; Booklet ; Front and rear brake discs and pads/linings: Checking
condition of discs and thickness of pads/linings .
❑ Always renew on both sides of an axle.
❑ Removing and installing ⇒ page 46 .
9 - Pad retainer
❑ Always renew when changing pads.
10 - Brake caliper
❑ Do not disconnect brake hose when changing pads.
❑ Removing and installing ⇒ page 49 .
❑ Repairing ⇒ page 68 .
❑ Basic setting must be carried out after repair work or renewal.
11 - Self-locking hexagon bolt, 35 Nm
❑ Renew.
12 - Bracket
13 - Brake line, 14 Nm
14 - Retaining clip
15 - Sealing ring
16 - Parking brake motor.
17 - Torx socket head bolt, 12 Nm
18 - Brake hose
19 - Torx socket head bolt, 12 Nm

2.2 Removing and installing brake pads/lin‐

ings
Special tools and workshop equipment required
♦ Vehicle diagnosis, testing and information system -VAS 5051-

46 Rep. gr.46 - Brakes - mechanism

 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

♦ Diagnosis cable -VAS 5051/1- or -VAS 5051/3-

♦ Torque wrench -V.A.G 1331-

♦ Piston resetting appliance -T10145-

Removing:
Mark brake pads when removing if they are to be reused. Fit in
same position when installing, or braking will be uneven.

Note

Do not separate connectors of parking brake motors.

• Electromechanical parking brake not operated.

– Remove wheels.
The electromechanical parking brake pistons must be moved
back with -VAS 5051- .
Before resetting pistons, draw off brake fluid from brake fluid res‐
ervoir. Otherwise, particularly if reservoir has been topped up,
fluid will overflow and cause damage.
– Connecting ⇒ Vehicle diagnostic tester and selecting functions
⇒ page 9 .

2. Rear brakes 47
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Brake systems - Edition 12.2011

– Do do this, select electromechanical parking brake and „mov‐

ing parking brake motor pistons forwards and backwards“
function.
– Move the pistons back using ⇒ Vehicle diagnostic tester.
– Then remove securing bolts from brake caliper; to do this,
counterhold on guide pin.
– Remove brake caliper from brake carrier.

Note

The resetting of the pistons with -VAS 5051- is still required but
is often not sufficient! The thrust nut in the piston is fitted on a
floating bearing, so that the piston can only be compressed but
not pulled back. Only the spindle with the thrust nut will be moved
back.

Caution

The piston must be reset beforehand with -VAS 5051- .

– Now press piston back fully with piston resetting tool -

T10145- .
– Secure brake caliper with wire so that weight of brake caliper
does not stress or damage brake hose.

– Remove brake pads and pad retainers -arrows-.

Cleaning:

WARNING

Do not blow out brake system with compressed air; the result‐
ing dust constitutes a health hazard!

– Thoroughly clean brake carrier and contact surfaces for brake

pads and remove corrosion.
– Clean brake caliper.
Use only methylated spirits for cleaning the brake caliper housing.
Installing:

48 Rep. gr.46 - Brakes - mechanism

 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

– Insert pad retainers -arrows- and brake pads into brake carrier.

– Ensure that brake pads are seated correctly in pad retainers

-arrows-.
– Secure brake caliper with new self-locking bolts.
♦ The repair kit includes four self-locking hexagon bolts which
must always be installed.
After moving the pistons forwards using -VAS 5051- , carry out a
basic setting of brake system.
– Carry out basic setting of brake system using -VAS 5051- .
– Fit wheels.
Specified torque for wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Wheels, tyres; Specified torque for wheel bolts .

Note

Check brake fluid level after changing brake pads.

Specified torque:
Hexagon bolt, brake caliper to brake carrier 35 Nm
♦ Use new bolts!

2.3 Removing and installing brake caliper

Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1331-

2. Rear brakes 49
 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

♦ Brake pedal depressor -V.A.G 1869/2-

♦ Vehicle diagnosis, testing and information system -VAS 5051-

♦ Diagnosis cable -VAS 5051/1- or -VAS 5051/3-

Removing:
This procedure applies only to exchanging or the following repair
work on the brake caliper.

Note

Do not separate connectors of parking brake motors.

– Remove wheels.
The electromechanical parking brake pistons must be moved
back with -VAS 5051- .
Before resetting pistons, draw off brake fluid from brake fluid res‐
ervoir. Otherwise, particularly if reservoir has been topped up,
fluid will overflow and cause damage.
– Connecting ⇒ Vehicle diagnostic tester and selecting functions
⇒ page 9 .
– Do do this, select electromechanical parking brake and „mov‐
ing parking brake motor pistons forwards and backwards“
function.
– Move the pistons back using ⇒ Vehicle diagnostic tester.
– Unscrew parking brake motor without separating the connec‐
tor.
– Connect bleeder bottle hose to brake caliper bleeder valve and
open bleeder valve.
– Apply brake pedal actuator -V.A.G 1869/2- .
– Close bleeder valve and remove bleeder bottle.
– Unscrew brake line from brake hose and brake caliper.

50 Rep. gr.46 - Brakes - mechanism

 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

– Remove both securing bolts from brake caliper; to do this,

counterhold on guide pin.
– Pull brake caliper off brake carrier.
Installing:
• The brake pads are seated in the retaining springs on the
brake carrier.
– Secure brake caliper to brake carrier with new self-locking
bolts.
The annular groove and the contact surface of the parking brake
motor must be clean.
– Install new sealing ring.
– Turn spindle back slightly, using a T45 Torx socket, until park‐
ing brake motor can be inserted correctly.
– Carefully position parking brake motor, ensuring that sealing
ring is seated.
– Turn parking brake motor until bolt hole and thread align.
Make sure that parking brake motor is flush with brake caliper.
Never pull parking brake motor onto brake caliper using securing
bolts.
– Position Torx bolts by hand and then tighten.
– Screw brake line to brake caliper.
– Bleed brake system ⇒ page 94 .
After moving the pistons forwards using -VAS 5051- , carry out a
basic setting of brake system.
– Carry out basic setting of brake system using -VAS 5051- .
– Fit wheels.
Specified torque for wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Wheels, tyres; Specified torque for wheel bolts .

Note

Check brake fluid level.

Specified torques:
Hexagon bolt, brake caliper to brake carrier 35 Nm
♦ Use new bolts!

Brake line to brake caliper 14 Nm

Parking brake motor to brake caliper 12 Nm

2. Rear brakes 51
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Brake systems - Edition 12.2011

3 Parking brake
⇒ „3.1 Fitting location overview - parking brake“, page 52
⇒ „3.2 Removing and installing control unit“, page 53
⇒ „3.3 Removing and installing parking brake motor“, page 53

3.1 Fitting location overview - parking brake

Electromechanical parking brake:

1 - Electromechanical parking
brake button -E538-
❑ Location: in dash panel,
next to light switch.
2 - Electromechanical parking
brake warning lamp -K213-
❑ Location: in electrome‐
chanical parking brake
button -E538- .
3 - Electric parking brake and
handbrake fault warning lamp
-K214-
❑ Location: in dash panel
insert.
4 - Brake system warning lamp
-K118-
❑ Location: in dash panel
insert.
5 - Acoustic signal
6 - Auto-hold button -E540-
❑ With auto-hold warning
lamp -K237-
❑ Location: in centre con‐
sole.
7 - Control unit for electrome‐
chanical parking brake -J540-
and ESP sensor unit -G419-
❑ Installed together in one
housing.
❑ Removing and installing
⇒ page 53 .
8 - Sealing ring
9 - Right parking brake motor -
V283-
❑ Location: on rear right brake caliper
❑ Removing and installing ⇒ page 53 .
10 - Torx socket head bolt, 12 Nm
11 - Left parking brake motor -V282-
❑ Location: on rear left brake caliper
❑ Removing and installing ⇒ page 53 .

Volkswagen Technical Site: http://vwts.ru http://vwts.info

52 Rep. gr.46 - Brakes - mechanism

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3.2 Removing and installing control unit

The control unit for electromechanical parking brake -J540- and
the ESP sensor unit -G419- are installed in a housing below the
centre console.
After the control unit for electromechanical parking brake -J540-
has been replaced together with the ESP sensor unit -G419- , it
is necessary to code the ABS control unit -J104- and to carry out
a basic setting of the „brake system“ (electromechanical parking
brake).

WARNING

Severe shocks (e.g. dropping, impact) may destroy the ESP

sensor unit -G419- . The ESP sensor unit -G419- may not then
be used any further.

Removing:
– Remove centre console ⇒ General body repairs, interior; Rep.
gr. 68 ; Centre console; Removing and installing centre con‐
sole .
– Remove the three securing nuts -arrows-.
– Pull connector -1- off control unit for electromechanical park‐
ing brake -J540- .
– Remove control unit for electromechanical parking brake -
J540- .
Installing:
– Install in reverse order.
When installing control unit for electromechanical parking brake
-J540- , ensure that it is correctly seated in its bracket and is free
of stress.

Note

Do not use the securing nuts to forcibly position control unit for
electromechanical parking brake -J540- .

– Tighten securing nuts to 9 Nm.

– Code control unit -J104- with ⇒ Vehicle diagnostic tester in
”Guided fault finding”.
To do this, carry out basic setting of steering angle sender -G85- ,
lateral acceleration sender -G200- , brake pressure sender -
G201- and longitudinal acceleration sender -G251- .
– Carry out basic setting of „brake system“ (electromechanical
parking brake).
Connecting ⇒ Vehicle diagnostic tester and selecting functions
⇒ page 9 .

3.3 Removing and installing parking brake

motor
Special tools and workshop equipment required

3. Parking brake 53
 CC 2010 ➤ , CC 2012 ➤ , Passat CC 2009 ➤
Brake systems - Edition 12.2011

♦ Torque wrench -V.A.G 1331-

♦ Vehicle diagnosis, testing and information system -VAS 5051-

♦ Diagnosis cable -VAS 5051/1- or -VAS 5051/3-

Removing:

Note

Switch off ignition for at least 30 seconds before disconnecting

connector.

– Pull connector -1- off parking brake motor.

54 Rep. gr.46 - Brakes - mechanism

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– Unscrew both Torx bolts -arrows- from parking brake motor.

– Pull parking brake motor off brake caliper.
– Remove sealing ring.
Take care not to damage annular groove for seal and contact
surface on parking brake motor.
– Clean annular groove and contact surface on parking brake
motor.
Installing:

– Slightly moisten new sealing ring with brake fluid, then fit.

– Turn spindle back slightly, using a T45 Torx socket -A-, until
parking brake motor can be inserted correctly.

Caution

The sealing ring must not be allowed to turn out while the park‐
ing brake motor is being installed!

– Carefully position parking brake motor, ensuring that sealing

ring is seated.
– Turn parking brake motor until bolt hole and thread align.
Make sure that parking brake motor is flush with brake caliper.
Never pull parking brake motor onto brake caliper using securing
bolts.

– Position Torx bolts -arrows- by hand and then tighten.

– Install connector.
– Perform basic brake system setting.
– Connecting ⇒ Vehicle diagnostic tester and selecting functions
⇒ page 9 .

3. Parking brake 55
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4 Brake pedal
⇒ „4.1 Assembly overview - brake pedal“, page 56
⇒ „4.2 Separating brake pedal from brake servo“, page 56
⇒ „4.3 Connecting brake pedal to brake servo“, page 57

4.1 Assembly overview - brake pedal

WARNING

The brake pedal travel must not be restricted by additional floor

coverings.

Grease all mountings before installing with grease Part No.

G 000 602.

1 - Mounting bracket
2 - Self-locking hexagon nut,
25 Nm
3 - Self-locking hexagon nut,
25 Nm
4 - Brake pedal
❑ Connect brake pedal to
brake servo plunger rod
⇒ page 57 .
5 - Cap
6 - Bearing shell
7 - Mounting
❑ For ball head of brake
servo plunger rod.
8 - Hexagon bolt
9 - Sleeve bearing
10 - Pivot pin

4.2 Separating brake pedal from brake ser‐

vo
Special tools and workshop equipment required

56 Rep. gr.46 - Brakes - mechanism

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♦ Release tool -T10159-

– Remove trim on driver side ⇒ General body repairs, interior;

Rep. gr. 68 ; Compartments/covers; Removing and installing
dash panel end trim on driver side .
– First press brake pedal in direction of brake servo and hold.
2 - Plunger rod
3 - Retaining lugs
– Insert release tool -T10159- and pull in direction of driver seat.
When doing this, counter-hold on brake pedal. (At this stage
the pedal must not be allowed to move backwards.) This action
will press retaining lugs -3- of mounting off ball head of plunger
rod -2-.
For the sake of clarity, separation of brake pedal from brake servo
is shown with pedal cluster removed.
– Pull release tool -T10159- and brake pedal together towards
driver seat. (This action will pull the brake pedal off the ball
head of the plunger rod).

4.3 Connecting brake pedal to brake servo

– Hold ball head of plunger rod in front of mounting and push
brake pedal in direction of brake servo, so that the ball head
clicks into place.
Continue installation in reverse order.

4. Brake pedal 57
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47 – Brakes - hydraulics
1 Front brake calipers
⇒ „1.1 Assembly overview - front brake caliper“, page 58
⇒ „1.2 Removing and installing brake caliper piston“, page 60

1.1 Assembly overview - front brake caliper

⇒ „1.1.1 Assembly overview - brake caliper FN3“, page 58
⇒ „1.1.2 Assembly overview - brake caliper FNR-G“, page 59
⇒ „1.1.3 Assembly overview - brake caliper C60“, page 59

1.1.1 Assembly overview - brake caliper FN3

♦ When carrying out repairs, install all parts supplied in repair
kit.
♦ Use only methylated spirits for cleaning the brake.
♦ Apply thin coat of assembly paste G 052 150 A2 to brake cyl‐
inder, piston and sealing ring.

1 - Dust cap
❑ Fit onto bleeder valve.
2 - Bleeder valve, 10 Nm
❑ Apply thin coat of as‐
sembly paste
G 052 150 A2 to thread
before screwing in.
3 - Cover caps
❑ Insert into sleeve bear‐
ing.
4 - Guide pin, 30 Nm
5 - Sleeve bearing
❑ Insert into brake caliper.
6 - Brake caliper
7 - Brake carrier
❑ Bolt onto brake caliper.
8 - Retaining spring
❑ Insert with both ends in
holes in brake caliper.
9 - Sealing ring
❑ Removing and installing
⇒ page 61 .
10 - Piston
❑ Removing and installing
⇒ page 61 .
❑ Apply thin coat of as‐
sembly paste
G 052 150 A2 to piston
before installing.
11 - Protective cap
❑ Removing and installing ⇒ page 61 .

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❑ Take care not to damage when inserting piston.

1.1.2 Assembly overview - brake caliper FNR-G

♦ When carrying out repairs, install all parts supplied in repair
kit.
♦ Use only methylated spirits for cleaning the brake.
♦ Apply thin coat of assembly paste G 052 150 A2 to brake cyl‐
inder, piston and sealing ring.

1 - Dust cap
❑ Fit onto bleeder valve.
2 - Bleeder valve, 12 Nm
❑ Apply thin coat of as‐
sembly paste
G 052 150 A2 to thread
before screwing in.
3 - Cover caps
❑ Insert into sleeve bear‐
ing.
4 - Guide pin, 30 Nm
5 - Sleeve bearing
❑ Insert into brake caliper.
6 - Brake caliper
❑ Must not be unscrewed
from one another.
7 - Retaining spring
❑ Insert into brake pad re‐
taining spring and press
under brake carrier.
8 - Brake carrier
❑ Bolt onto brake caliper.
9 - Sealing ring
❑ Removing and installing
⇒ page 63 .
10 - Piston
❑ Removing and installing
⇒ page 63 .
❑ Apply thin coat of as‐
sembly paste
G 052 150 A2 to piston
before installing.
11 - Protective cap
❑ Removing and installing ⇒ page 63 .
❑ Take care not to damage when inserting piston.

1.1.3 Assembly overview - brake caliper C60

♦ When carrying out repairs, install all parts supplied in repair
kit.
♦ Use only methylated spirits for cleaning the brake.

1. Front brake calipers 59

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♦ Apply thin coat of assembly paste G 052 150 A2 to brake cyl‐

inder, piston and sealing ring.

1 - Dust cap
❑ Fit onto bleeder valve.
2 - Bleeder valve, 13 Nm
❑ Apply thin coat of as‐
sembly paste
G 052 150 A2 to thread
before screwing in.
3 - Hexagon bolt, 35 Nm
❑ Always renew after re‐
moving.
4 - Guide pin
5 - Protective cap
❑ Insert into brake carrier
and guide pin groove;
grease groove before‐
hand, use repair kit
grease pack.
6 - Brake carrier
❑ Supplied as replace‐
ment part, assembled
with guide pin and pro‐
tective caps, and with
sufficient grease on
guide pins.
❑ If protective caps or
guide pins are dam‐
aged, install repair kit.
Use lubricant sachet
supplied to lubricate
guide pins.
7 - Protective cap
❑ Removing and installing
⇒ page 65 .
❑ Take care not to dam‐
age when inserting piston.
8 - Piston
❑ Removing and installing ⇒ page 65 .
❑ Apply thin coat of assembly paste G 052 150 A2 to piston before installing.
9 - Sealing ring
❑ Removing and installing ⇒ page 65 .
10 - Brake caliper

1.2 Removing and installing brake caliper

piston
⇒ „1.2.1 Removing and installing piston for brake caliper FN 3“,
page 61
⇒ „1.2.2 Removing and installing piston for FNR-G brake caliper“,
page 63
⇒ „1.2.3 Removing and installing piston for brake caliper C 60“,
page 65

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1.2.1 Removing and installing piston for brake

caliper FN 3
Special tools and workshop equipment required
♦ Removal wedge -3409-

♦ Piston resetting appliance -T 10145-

♦ Assembly tool for protective caps -T10146/6-

Removing:
– Press piston out of brake caliper using compressed air.
Place a piece of wood in the recess to prevent damage to the
piston.

1. Front brake calipers 61

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– Lever off protective cap from brake caliper using wedge 3409.

– Remove seal using wedge 3409.

When removing ensure that the surface of the cylinder is not
damaged.
Installing:
– The surfaces of the piston and seal must be cleaned only with
methylated spirits and then dried.
– Apply a thin coat of assembly paste G 052 150 A2 to piston
and seal before inserting.
– Insert seal into brake caliper.

– Fit protective seal -A- in assembly tool T10146/6 -1-.

– Press protective cap onto brake caliper so that seal is fitted

correctly all round using assembly tool -1- and piston resetting
tool -2-.
Check seat of protective cap:

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– At this stage it should not be possible to remove protective cap

from brake caliper by hand.

– Press piston lightly onto protective seal and lock it in this po‐
sition with, for example, an assembly wedge -2-.
Keep piston straight to prevent damage to sealing collar.
– Blow into protective cap using compressed air (max 3 bar)
-1-. During this step protective cap will spring on piston.

– Press piston into brake caliper using piston resetting appliance

-1-.
The outer sealing lip on the protective cap will then slip into the
piston groove.

1.2.2 Removing and installing piston for FNR-

G brake caliper
Special tools and workshop equipment required
♦ Removal wedge -3409-

1. Front brake calipers 63

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♦ Piston resetting appliance -T 10145-

♦ Assembly tool for protective caps -T 10146/6-

Removing:
– Press piston out of brake caliper using compressed air.
Place a piece of wood in the recess to prevent damage to the
piston.
– Lever off protective cap from brake caliper using wedge 3409.

– Remove seal using wedge 3409.

When removing ensure that the surface of the cylinder is not
damaged.
Installing:
– The surfaces of the piston and seal must be cleaned only with
methylated spirits and then dried.
– Apply a thin coat of assembly paste G 052 150 A2 to piston
and seal before inserting.

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– Insert seal into brake caliper.

– Fit protective cap -A- in assembly tool T10146/1 -1-.

– Press protective cap onto brake caliper so that seal is fitted

correctly all round using assembly tool -1- and piston resetting
tool -2-.
Check seat of protective cap:
– At this stage it should not be possible to remove protective cap
from brake caliper by hand.

– Gently press piston onto protective seal using an extension

and ratchet insert -1- and then hold in this position.
Keep piston straight to prevent damage to sealing collar.
– Blow into protective cap using compressed air (max 3 bar)
-2-. During this step protective cap will spring on piston.
– Press piston into brake caliper by hand, subsequently press‐
ing with piston resetting tool if necessary.
The outer sealing lip on the protective cap will then slip into the
piston groove.

1.2.3 Removing and installing piston for brake

caliper C 60
Special tools and workshop equipment required

1. Front brake calipers 65

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♦ Removal wedge -3409-

♦ Piston resetting appliance -T10145-

Removing:
– Press piston out of brake caliper using compressed air.
Place a piece of wood in the recess to prevent damage to the
piston.

– Remove seal using wedge 3409.

When removing ensure that the surface of the cylinder is not
damaged.
Installing:
– The surfaces of the piston and seal must be cleaned only with
methylated spirits and then dried.
– Apply a thin coat of assembly paste G 052 150 A2 to piston
and seal before inserting.
– Insert seal in brake caliper.

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– Place protective cap with outer sealing lip on piston.

– Insert inner sealing lip into groove in cylinder using wedge

3409.
When doing this, hold piston in front of brake caliper.

– Press piston into brake caliper using piston resetting tool.

The outer sealing lip on the protective cap will then slip into the
piston groove.

1. Front brake calipers 67

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2 Rear brake calipers

⇒ „2.1 Assembly overview - rear brake caliper“, page 68
⇒ „2.2 Removing and installing rear brake caliper piston“,
page 69

2.1 Assembly overview - rear brake caliper

♦ When carrying out repairs, install all parts supplied in repair
kit.
♦ Use only methylated spirits for cleaning the brake.
♦ New brake calipers are filled with brake fluid and are pre-bled.
♦ Apply thin coat of assembly paste G 052 150 A2 to brake cyl‐
inder, piston and sealing ring.
♦ When repairs are performed, it is essential to appropriately
pre-bleed brake calipers (without brake pads) before installing
in vehicle ⇒ page 71 .

1 - Brake caliper
❑ Following repair work,
pre-bleed brake caliper
⇒ page 71 .
2 - Self-locking hexagon bolt,
35 Nm
❑ Renew.
❑ When loosening and
tightening, counterhold
on guide pin.
3 - Dust cap
4 - Bleeder valve, 10 Nm
❑ Apply thin coat of as‐
sembly paste
G 052 150 A2 to thread
before screwing in.
5 - Torx socket head bolt, 12
Nm
6 - Parking brake motor.
7 - Sealing ring
8 - Guide pin
❑ Grease before fitting
protective cap.
9 - Protective cap
❑ Fit onto brake carrier
and guide pin.
10 - Brake carrier with guide
pin(s) and protective cap
❑ Supplied as genuine
part, assembled with
sufficient grease on
guide pins.
❑ If protective caps or guide pins are damaged, install repair kit. Use lubricant sachet supplied to lubricate
guide pins.

68 Rep. gr.47 - Brakes - hydraulics

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11 - Protective cap
❑ Pull on so that outer sealing lip goes over piston.
❑ Removing and installing ⇒ page 69 .
12 - Piston
❑ Removing and installing ⇒ page 69 .
❑ Apply thin coat of assembly paste G 052 150 A2 to piston before installing.
13 - Sealing ring
❑ Removing and installing ⇒ page 69 .
14 - Thrust nut

2.2 Removing and installing rear brake cal‐

iper piston
Special tools and workshop equipment required
♦ Removal wedge -3409-

Removing:
– Turn spindle -movement arrow- using a T45 Torx socket.
The thrust nut pushes the piston out of the brake caliper.
– Remove piston and protective cap from brake caliper.

– Remove seal using wedge 3409.

Installing:
– The surfaces of the piston and seal must be cleaned only with
methylated spirits and then dried.
– Apply a thin coat of assembly paste G 052 150 A2 to piston
and seal before inserting.
– Insert seal in brake caliper.

2. Rear brake calipers 69

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– Place protective cap with outer sealing lip on piston.

– Screw thrust nut onto spindle until dimension -a- 15 mm is

achieved.

– Insert inner sealing lip of protective cap into groove -arrows-

in brake caliper using removal wedge -3409- .
– Push piston onto thrust nut; this is only possible in four posi‐
tions.
– Carefully push piston into brake caliper, whilst moving piston.

– Now push piston into brake caliper until it rests on thrust nut.

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– Carefully turn spindle clockwise until thrust nut is located on

stop.

– Ensure that protective cap lies flush all around on brake caliper
-arrows-.

– Press piston into brake caliper by hand.

The outer sealing lip will then spring into the piston groove.

2.2.1 Pre-bleeding brake caliper

– Open bleeder valve -arrow A- and, using a commercially avail‐
able bleeder bottle, fill with brake fluid until bubble-free brake
fluid flows from threaded hole of brake hose connection
-arrow B-. Close bleeder valve.
Position brake caliper as illustrated to pre-bleed.

2. Rear brake calipers 71

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3 Brake servo and brake master cylin‐

der
⇒ „3.1 Assembly overview - brake servo/brake master cylinder“,
page 72
⇒ „3.2 Removing and installing brake light switch“, page 73
⇒ „3.3 Removing and installing brake master cylinder“,
page 74
⇒ „3.4 Removing and installing brake servo“, page 75

3.1 Assembly overview - brake servo/brake

master cylinder

Note

Use only new brake fluid. Observe information on brake fluid res‐
ervoir!

1 - Pedal cluster
2 - Self-locking hexagon nut,
25 Nm
❑ Always renew after re‐
moving.
3 - Seal
❑ For brake servo.
4 - Brake servo
❑ On petrol engines, the
required vacuum is tak‐
en from the intake mani‐
fold.
❑ Vehicles with an FSI en‐
gine but no HBV are fit‐
ted with a pressure sen‐
sor ⇒ page 81 .
❑ A vacuum sender is fit‐
ted in vehicles with HBV
⇒ page 24 .
❑ Diesel engines are fitted
with a vacuum pump to
generate the necessary
vacuum pressure
⇒ page 80 .
❑ Functional check:
– With engine switched
off, depress brake pedal
firmly several times (to
exhaust vacuum in unit).

– Now step on and hold

brake pedal with medi‐
um pressure and start
engine. If the brake ser‐
vo is functioning proper‐
ly, the brake pedal will
be felt to go down as the servo takes effect.

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❑ Replace completely in the event of a fault (before doing so, check brake servo vacuum system)
⇒ page 82
❑ Removing and installing ⇒ page 75 .
5 - Sealing ring
6 - Brake servo vacuum sender -G483-
❑ Only on vehicles having HBV
❑ Removing and installing ⇒ page 24 .
7 - Brake master cylinder
❑ Cannot be repaired. If faulty, renew as a complete unit.
❑ Removing and installing ⇒ page 74 .
8 - Brake light switch -F-
❑ Removing and installing ⇒ page 73 .
9 - Torx socket head bolt, 5 Nm
10 - Heat shield
11 - Self-locking hexagon nut, 25 Nm
❑ Always renew after removing.
12 - Brake line, ∅ 6 mm, 14 Nm
❑ From secondary piston circuit of brake master cylinder to hydraulic unit.
13 - Brake line, ∅ 6 mm, 14 Nm
❑ From primary piston circuit of brake master cylinder to hydraulic unit.
14 - Sealing plug
❑ Moisten with brake fluid and press into brake fluid reservoir.
15 - Brake fluid reservoir
16 - Cap
17 - Vacuum hose
❑ With non-return valve and, additionally on vehicles with FSI engine but without HBV (hydraulic brake with
vacuum servo), brake servo pressure sensor -G294-
❑ Fit in brake servo.
❑ Removing and installing brake servo pressure sensor -G294- ⇒ page 81
18 - Sealing plug
❑ Connection for vacuum hose.

3.2 Removing and installing brake light

switch
Removing
– Note or request radio code on vehicles with coded radio if
necessary.
– Disconnect battery. ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
– Remove intake hose, air filter housing (on vehicles with diesel
engine and certain petrol engines) and battery ⇒ Electrical
system; Rep. gr. 27 ; Battery; Removing and installing battery .
The battery is installed in the luggage compartment on vehicles
with a 6-cylinder petrol engine and therefore only the air filter
housing must be removed.
– Remove battery tray.

3. Brake servo and brake master cylinder 73

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– Separate connector -1- from brake light switch -F- .

– Remove bolt -2- from brake master cylinder.
– Pull brake light switch -F- -3- from brake master cylinder at top
and remove from clip at bottom.
Installing
– Install in reverse order.
Specified torque:
Torx bolt to brake master cylinder 5 Nm

3.3 Removing and installing brake master

cylinder
Special tools and workshop equipment required
♦ Brake filling and bleeding equipment -VAS 5234-

♦ Torque wrench -V.A.G 1331-

Removing:
– Note or request radio code on vehicles with coded radio if
necessary.
– Disconnect battery. ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
– Remove intake hose, air filter housing (on vehicles with diesel
engine and certain petrol engines) and battery ⇒ Electrical
system; Rep. gr. 27 ; Battery; Removing and installing battery .
The battery is installed in the luggage compartment on vehicles
with a 6-cylinder petrol engine and therefore only the air filter
housing must be removed.
– Remove battery tray.
– Place sufficient lint-free cloths in area of engine and gearbox.

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– Draw off as much brake fluid as possible from brake fluid res‐
ervoir using brake filling and bleeding equipment -VAS 5234- .
Vehicles with manual gearbox:
– Detach supply hose -B- for clutch master cylinder, lift clear and
tie in place, or clamp off supply hose -B- for clutch master cyl‐
inder with a commercially available tool, e.g. Hazet 4590, and
then pull off.
Continuation for all models:
– Disconnect connector -A- from brake fluid level warning con‐
tact -F34- .
– Separate connector -C- from brake light switch -F- .

– Remove brake fluid reservoir. To do this press locking tabs on

reservoir outwards and simultaneously pull brake fluid reser‐
voir out of sealing plugs.
– Disconnect brake lines -1- on brake master cylinder and seal
brake lines with plugs from repair kit Part No. 1H0 698 311 A.
– Remove nuts -2- from brake master cylinder.
– Remove heat shield (if installed).
– Carefully take brake master cylinder out of brake servo.
– Unscrew brake light switch -F- from brake master cylinder.
Installing:
– Install in reverse order.
Observe the following important points when installing:
– When assembling brake master cylinder with brake servo,
make sure plunger rod is properly positioned in brake master
cylinder.
– Bleed brake system ⇒ page 94 .
Specified torques:
Brake master cylinder to brake servo 25 Nm
♦ Use new nuts.

Brake light switch to brake master cylinder 5 Nm

Brake lines to brake master cylinder, ∅ 6 mm 14 Nm

3.4 Removing and installing brake servo

Note

If there are problems with the brake servo, first check the brake
servo vacuum system ⇒ page 82

Special tools and workshop equipment required

3. Brake servo and brake master cylinder 75

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♦ Brake filling and bleeding equipment -VAS 5234-

♦ Torque wrench -V.A.G 1331-

Removing:
– Note or request radio code on vehicles with coded radio if
necessary.
– Disconnect battery. ⇒ Electrical system; Rep. gr. 27 ; Battery;
Disconnecting and connecting battery .
– Remove intake hose, air filter housing (on vehicles with diesel
engine and certain petrol engines) and battery ⇒ Electrical
system; Rep. gr. 27 ; Battery; Removing and installing battery .
The battery is installed in the luggage compartment on vehicles
with a 6-cylinder petrol engine and therefore the air filter housing
with bracket must be removed. In addition, unbolt slave start box
with bracket and lay to side.
– Remove battery tray.
– Place sufficient lint-free cloths in area of engine and gearbox.
– Draw off as much brake fluid as possible from brake fluid res‐
ervoir using brake filling and bleeding equipment -VAS 5234- .

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Vehicles with manual gearbox:

– Detach supply hose -B- for clutch master cylinder, lift clear and
tie in place, or clamp off supply hose -B- for clutch master cyl‐
inder with a commercially available tool, e.g. Hazet 4590, and
then pull off.
Continuation for all models:
– Disconnect connector -A- from brake fluid level warning con‐
tact -F34- .
– Separate connector -C- from brake light switch -F- .
– On vehicles with HBV, pull connector off brake servo vacuum
sender -G483- .
– Pull vacuum hose out of brake servo.
Vehicles with manual gearbox:

– Release cables -1-, unbolt support bracket -2- and place it to

side ⇒ Rep. gr. 34 ; Selector mechanism; Assembly overview
- selector cables .
On vehicles with 2.0 l TDI engine:
– Remove air pipe and pull it as far as possible in front of gear‐
box ⇒ Rep. gr. 21 ; Charge air system; Assembly overview -
charge air system .
On vehicles with automatic gearbox 09G:

On this automatic gearbox the ATF cooler is located directly in

front of the brake servo; see the following illustration.
– Fit support bracket -10 - 222 A- and support engine/gearbox
assembly. Do not raise ⇒ 6-speed automatic gearbox 09G;
Rep. gr. 37 ; Removing and installing gearbox .
– Remove noise insulation tray.

– Remove pendulum support, first -A-, then -B-.

(First tighten -B-, then -A- when installing.) Specified torques ⇒
Running gear, axles, steering; Rep. gr. 40 ; Subframe; Assembly
overview - subframe .
– Lever selector lever cable off, remove from support bracket
and from retainer and place to side ⇒ Automatic gearbox; Rep.
gr. 37 ; Selector mechanism; Removing and installing selector
lever cable .
– Open cable duct and remove Servotronic wiring harness.
Then remove cable duct from console and place it to side.
– Remove both bolts securing gearbox bracket to vehicle.
– Slightly lower engine/gearbox assembly by turning spindle of
support bracket -10 - 222 A- .

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– Also pull vacuum hose -2- off vacuum pump -1-.

– Unbolt retainer for a wiring harness from vacuum pump -1-.
On vehicles with automatic gearbox 09M:
– Open cable duct and remove Servotronic wiring harness.
Then remove cable duct from console and place it to side.
– Lever selector lever cable off, remove from support bracket
and from retainer and place to side ⇒ Automatic gearbox; Rep.
gr. 37 ; Selector mechanism; Removing and installing selector
lever cable .

– Remove retainer from selector lever cable.

Continuation for all models:
– Unscrew brake lines on brake master cylinder and seal brake
lines with plugs from repair kit Part No. 1H0 698 311 A.
Additionally for vehicles with 6-cylinder petrol engine:
– Remove nuts for brake master cylinder.
– Carefully remove brake master cylinder from brake servo and
also remove heat shield.
– Remove brake servo vacuum sender -G483- ⇒ page 24 .
Continuation for all models:
– Remove driver side footwell cover ⇒ General body repairs,
interior; Rep. gr. 68 ; Compartments/covers; Removing and
installing dash panel end trim on driver side .

– Unscrew securing nuts -arrows- and remove footwell trim -1-.

– Separate brake pedal from brake servo ⇒ page 56 .

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– Unscrew nuts -1- from brake servo.

– Remove both upper nuts -2- from mounting bracket.
– Carefully remove brake servo from vehicle.
– Remove nuts for brake master cylinder.
– Carefully remove brake master cylinder from brake servo.
Installing:
– Install in reverse order.
Observe following points when installing:
– Connect brake pedal to brake servo ⇒ page 57 .
– After installing, bleed brake system ⇒ page 94 and clutch.
Specified torques:
Brake servo to pedal cluster and bulkhead 25 Nm
♦ Use new nuts.

Brake master cylinder to brake servo 25 Nm

♦ Use new nuts.

Brake lines to brake master cylinder, ∅ 6 mm 14 Nm

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4 Vacuum system
⇒ „4.1 Assembly overview - vacuum pump“, page 80
⇒ „4.2 Checking non-return valve“, page 81
⇒ „4.3 Removing and installing brake servo pressure sensor“,
page 81
⇒ „4.4 Checking brake servo vacuum system“, page 82

4.1 Assembly overview - vacuum pump

⇒ „4.1.1 Vacuum pump for brake servo (vehicles with diesel en‐
gine)“, page 80
⇒ „4.1.2 Vacuum pump for brake servo (vehicles with petrol en‐
gine)“, page 81

4.1.1 Vacuum pump for brake servo (vehicles

with diesel engine)
Vacuum pump for 4-cylinder diesel engine (4-valve):
Must not be dismantled.
Tandem pump -4- (vacuum pump and fuel pump)
Vacuum hose to brake servo -1- with non-return valve.
Fuel lines -2 and 3-.
Vacuum pump for 4-cylinder diesel engine (4-valve, common rail):

Must not be dismantled.

Vacuum pump -2-.
Vacuum hose to brake servo -1- with non-return valve.

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4.1.2 Vacuum pump for brake servo (vehicles

with petrol engine)
Vacuum pump for 4-cyl. petrol engine:
Must not be dismantled.
Vacuum pump -1-.
Vacuum hose to brake servo -2- with non-return valve.
High-pressure pump -3-.
– Removing and installing vacuum pump ⇒ Rep. gr. 15 ; Cyl‐
inder head; Removing and installing vacuum pump .
Vacuum pump for 6-cyl. petrol engine:

Must not be dismantled.

Vacuum pump -B-.
Vacuum hose to brake servo -A- with non-return valve.
– Removing and installing vacuum pump ⇒ Rep. gr. 15 ; Cyl‐
inder head; Removing and installing vacuum pump .

4.2 Checking non-return valve

♦ Air must pass through non-return valve -A- in direction of ar‐
row.
♦ Non-return valve must remain closed in opposite direction.
Observe correct installation position!

4.3 Removing and installing brake servo

pressure sensor
– Remove engine cover panel.
– Pull vacuum hose together with brake servo pressure sensor
-G294- out of brake servo.

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– Release clips with pliers -1-.

– Carefully lever off brake servo pressure sensor -G294- -2-.

4.4 Checking brake servo vacuum system

The following instructions are intended to help you find the causes
of problems effectively and objectively in the event of complaints
about the brake servo or in the event of a so-called »hard brake
pedal«.
This check relates to the following components:
♦ Brake servo
♦ Oil seal between brake master cylinder and brake servo.
♦ Non-return valve
♦ Vacuum hoses with connectors
♦ Vacuum pump (if there is one)
When evaluating the measuring results, bear in mind that they will
be influenced by the geographical location. The higher your lo‐
cation is above sea level, the lower the air pressure will be.
Before checking the vacuum system, please take note of the fol‐
lowing prerequisites for checking:
♦ Visual inspection of all vacuum hoses for damage (e.g. cracks
or marten bite) and to check that they are correctly and firmly
attached
♦ Ensure cleanliness when working on vacuum system
♦ Before starting work, clean engine compartment if necessary
Special tools and workshop equipment required
♦ Vacuum gauge for brake servo -VAS 6721-

4.4.1 Connecting vacuum gauge for brake

servo -VAS 6721-
– Pull vacuum hose out of brake servo.

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First press the brake pedal several times in order to facilitate re‐
moval of the vacuum hose.
– Place brake servo vacuum gauge -VAS 6721- between them
-see following illustrations-.
Item Com‐ Explanation
num‐ po‐
ber nent
A Cut- In direction of vacuum hose, non-return valve and,
off if there is one, vacuum pump
valve
B Cut- ♦ Open to facilitate removal of brake servo vac‐
off uum gauge -VAS 6721-
valve
♦ Open to simulate a fault source
♦ Connection of manual vacuum pump -VAS
6213-

C Cut- In direction of brake servo

off
valve

– Push hose -A- of brake servo vacuum gauge -VAS 6721- onto
vacuum hose and press adapter -C- into brake servo.

4.4.2 Checking vacuum generation

Note

♦ The average air pressure of the earth's atmosphere at sea

level is 1013 mbar and decreases steeply as the altitude in‐
creases (approx. 100 mbar/1,000 m altitude). Local and time
fluctuations also influence vacuum generation.
♦ A cold engine, a switched-on air-conditioning system as well
as engine idling have an adverse influence on generation of a
vacuum.

– Before starting work, check all vacuum hoses for damage (e.g.
cracks or marten bite) and to check that they are correctly and
firmly attached
– Connect brake servo vacuum gauge -VAS 6721- ⇒ page 82 .
– Open cut-off valve -A-.

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– Close cut-off valves -B+C-.

– Start warm engine (>60° C), press accelerator briefly (engine
speed greater than 2000/min).
– Read indicated measured value.
Normally (see notes), the vacuum that is generated should be
between 600 and 950 mbar (depending on engine size).
If the measured value is not reached even through the precondi‐
tions (see notes) have been met, the vacuum system must first
be checked for leaks.
– For comparison purposes, generate the vacuum with the man‐
ual vacuum pump -VAS 6213- ⇒ page 86 .
Open cut-off valve -B- to facilitate removal of hose connections
and adapter.

4.4.3 Checking for leaks

Note

♦ The average air pressure of the earth's atmosphere at sea

level is 1013 mbar and decreases steeply as the altitude in‐
creases (approx. 100 mbar/1,000 m altitude). Local and time
fluctuations also influence vacuum generation.
♦ A cold engine, a switched-on air-conditioning system as well
as engine idling have an adverse influence on generation of a
vacuum.

– Before starting work, check all vacuum hoses for damage (e.g.
cracks or marten bite) and to check that they are correctly and
firmly attached
– Connect brake servo vacuum gauge -VAS 6721- ⇒ page 82 .
– Open cut-off valve -A-.
– Close cut-off valves -B+C-.
– Start warm engine (>60° C), press accelerator briefly (engine
speed greater than 2000/min).
Normally (see notes), the vacuum that is generated should be
between 600 and 950 mbar (depending on engine size).

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– Open cut-off valve -C- to evacuate brake servo.

– Switch off engine.
– Read and make a note of measured value shown.
A vacuum decrease of 400 mbar in 12 hours is permissible.
If the vacuum decrease is greater, check for leaks in the vicinity
of...
1- Brake servo
or
2- non-return valve, vacuum hoses with connectors or vacuum
pump/intake pipe
.
If there are large leaks, the vacuum decreases steeply within a
few seconds.
Vacuum check in vicinity of brake servo:

– After generation of vacuum, close cut-off valve -A- in order to

check brake servo vacuum system.
Vacuum check in vicinity of non-return valve, vacuum hoses with
connectors and vacuum pump/intake pipe:

– After generation of a vacuum, close cut-off valve -C- in order

to check vacuum system from brake servo vacuum gauge -
VAS 6721- to intake pipe or to vacuum pump.
Open cut-off valve -B- to facilitate removal of hose connections
and adapter.

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4.4.4 Vacuum generation with manual vac‐

uum pump -VAS 6213-
Instead of vacuum generation by means of engine or vacuum
pump, the vacuum can be generated with the manual vacuum
pump -VAS 6213- in certain cases.
– To do this, connect manual vacuum pump -VAS 6213- to vac‐
uum hose from connection -B- on brake servo vacuum gauge
-VAS 6721- .
– Open cut-off valve -B-.
– Generate vacuum with hand vacuum pump -VAS 6213- until
between 600 and 950 mbar is shown on brake servo vacuum
gauge -VAS 6721- .
– Then, carry out the corresponding checks.

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5 Brake lines
⇒ „5.1 Repairing brake lines“, page 87

5.1 Repairing brake lines

The flanging tool for brake lines -VAS 6056- can be used to flange
brake lines with an outer pipe diameter of 5 mm without damaging
the coating. In certain cases, this allows sections of brake lines
to be renewed at less expense.
The use of flanging tool V.A.G. 1356 is not permitted due to the
coating and the diameter of the black brake lines.

Note

♦ Brake lines may only be bent to max. 90°, as they otherwise

kink or display deformations which constrict the cross-section
of the line to an impermissible degree.
♦ Preferably separate brake lines at vehicle floor.
♦ The positions of the intermediate pieces must be selected so
that they cannot chafe on moving parts.
♦ Do not grease spindle; merely clean with methylated spirits.

Special tools and workshop equipment required

♦ Flanging tool for brake lines -VAS 6056-

♦ Brake filling and bleeding equipment -VAS 5234-

List of individual tools:

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1 - Flanging tool -VAS 6056/1-

❑ Flanging tool -VAS
6056/1- contains flang‐
ing jaws -VAS 6056/6-
2 - Pipe cutter -VAS 6056/2-
3 - Brake line scraper -VAS
6056/3-
❑ Grub screws (in shaft
and at side) are adjus‐
ted and must not be
readjusted!
4 - Set of grips with plastic jaws
-VAS 6056/4-
5 - Pipe bending tool -VAS
6056/5-
6 - Special wrench, 6 mm
7 - Flanging jaws -VAS 6056/7-

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5.1.1 Assembly overview - flanging tool

1 - Flanging tool upper part

❑ Unbolt to change flang‐
ing jaws
2 - Fastening for handle
❑ Must be removed to ac‐
cess retaining screw for
upper part
3 - Retaining screw
❑ For flanging tool upper
part
4 - Grub screws for flanging
jaws
❑ For centring and holding
flanging jaws
❑ Hexagon socket head
bolt, 2 mm
5 - Flanging jaws
❑ Various
❑ Assembly instructions
⇒ page 89

Flanging jaw 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 flanging jaws must point to
the edge of the housing, and the straight side of the flanging jaws
must be installed towards the spindle, or the flange will not be
formed correctly.

5.1.2 Work instructions

– Unbolt relevant brake line at brake caliper or wheel brake cyl‐
inder; catch escaping brake fluid and dispose of this as per
regulations.

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– Cut through brake line at a suitable point (straight, freely ac‐

cessible section) with pipe cutter -2-.
– Remove section to be renewed.
– Degrease brake line surface.

– Clamp brake line tightly in set of grips -4- so that approx. 50

mm project from plastic jaws.
– Clamp scraper -3- into a drill and position onto brake line.
– At slow drill speed and with gentle pressure on brake line,
scrape coating off brake line.
Length of scraping is determined by stop in scraper.
– Withdraw scraper from brake line and remove residue from
scraping.

– Remove set of grips and slide union bolt -D- onto brake line.

– Slide brake line -B- up to stop -A- in flanging tool.

Note

Brake line must be positioned against stop when the hexagon

socket head bolts are tightened, or the flange will not be formed
correctly.

– Tighten brake line in flanging tool until brake line can no longer
be moved. Fold up stop -A- and now tighten hexagon socket
head bolts diagonally using special wrench -C-.

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– Turn spindle to stop in flanging tool.

– Turn spindle back again.
– Loosen hexagon socket head bolts diagonally.
– Remove brake line from flanging tool, clean and check brake
line and flange.
Briefly flush the section of brake line remaining in the vehicle:
– Connect brake filling and bleeding unit -VAS 5234- , connect
bleeder bottle hose to brake line flange and allow brake filling
and bleeding unit -VAS 5234- to run briefly until a little brake
fluid has run through.
– Blow out new brake line to be inserted with compressed air.

– Join brake lines using connector -E-.

– Install brake line.
– Bleed brake system ⇒ page 94 .

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6 Hydraulic system
⇒ „6.1 General notes on brake fluid“, page 92
⇒ „6.2 Pre-bleeding hydraulic system“, page 92
⇒ „6.3 Bleeding hydraulic system following standard procedure“,
page 94
⇒ „6.4 Subsequent bleeding of hydraulic system“, page 95
⇒ „6.5 Testing for leaks“, page 95

6.1 General notes on brake fluid

WARNING

Only use new brake fluid conforming to VW standard

(VW 501 14).

Note

♦ Brake fluid is poisonous. Also due to its corrosive effect brake

fluid must not come into contact with paintwork.
♦ Brake fluid is hygroscopic, which means it absorbs moisture
from the ambient air and should therefore always be stored in
air-tight containers.
♦ Rinse off spilled brake fluid using plenty of water.

6.1.1 Changing brake fluid

⇒ Maintenance ; Booklet ; Brake and clutch system: Changing
brake fluid

6.2 Pre-bleeding hydraulic system

Bleeding the hydraulic system is described using brake filling and
bleeding equipment -VAS 5234- .
A pre-pressure of 2 bar is required for bleeding the ABS hydraulic
unit -N55- .
Special tools and workshop equipment required
♦ Brake filling and bleeding equipment -VAS 5234-

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♦ Tool set for brake bleeding -VAS 6564-

Carry out pre-bleeding when:

♦ in vehicles with EDL, EDL/TCS or EDL/TCD/ESP a chamber
in the brake fluid reservoir is completely empty. This occurs
e.g. in the case of brake system leaks.
Additional work for vehicles with diesel engine:
– Unbolt pressure converter or solenoid valve block from brack‐
et and lay to side.
Continuation for all models:
– Connect brake filling and bleeding equipment -VAS 5234- .
Bleeding sequence:
1 - Bleed front left and front right brake calipers simultaneously.

2 - Bleed rear left and rear right brake calipers simultaneously.

– Leave bleeder valves open with brake fluid hoses connected
until brake fluid free from air bubbles flows out.
Hydraulic unit must then be bled again by means of the function
„Basic setting“ with the ⇒ Vehicle diagnostic tester.
Initiate basic setting (to bleed brake system):
Connecting ⇒ Vehicle diagnostic tester and selecting functions
⇒ page 9 .
– Then bleed brake system as normal.

Volkswagen Technical Site: http://vwts.ru http://vwts.info

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6.3 Bleeding hydraulic system following

standard procedure
Bleeding the hydraulic system is described using brake filling and
bleeding equipment -VAS 5234- .
A pre-pressure of 2 bar is required for bleeding the ABS hydraulic
unit -N55- .
Special tools and workshop equipment required
♦ Brake filling and bleeding equipment -VAS 5234-

♦ Tool set for brake bleeding -VAS 6564-

Note

If, in vehicles with EDL, EDL/TCS or EDL/TCS/ESP, a chamber

in brake fluid reservoir is completely empty (e.g. brake system
leaking), brake system must be pre-bled first ⇒ page 92 .

Carry out the following work:

Additional work for vehicles with diesel engine:
– Unbolt pressure converter or solenoid valve block from brack‐
et and lay to side
Continuation for all models:
Adhere strictly to work sequence when bleeding brake system.
– Connect brake filling and bleeding equipment -VAS 5234- .
– Open bleeder valves in specified order and bleed brake cali‐
pers.
1 - Front left brake caliper
2 - Front right brake caliper
3 - Rear left brake caliper

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4 - Rear right brake caliper

Use suitable bleeder hose. It must sit tightly on bleeder valve so
that no air can enter brake system.
– Leave bleeder valve of each brake caliper open with bleeder
hose fitted until brake fluid discharges free of air bubbles.

6.4 Subsequent bleeding of hydraulic sys‐

tem
Carry out subsequent bleeding when:
♦ brake pedal travel is too long or so-called »soft brake pedal«
Subsequent bleeding requires the assistance of a second me‐
chanic.
– Depress brake pedal firmly and hold.
– Open bleeder valve on brake caliper.
– Fully depress brake pedal.
– Close bleeder valve with pedal held down.
– Release brake pedal slowly.
This bleed sequence must be carried out 5 times per brake cali‐
per.
Bleeding sequence:
1 - Front left brake caliper
2 - Front right brake caliper
3 - Rear left brake caliper
4 - Rear right brake caliper
A road test must be carried out after the brakes have been bled.
When doing this an ABS regulation must be performed at least
once!

6.5 Testing for leaks

Special tools and workshop equipment required
♦ Tester for brake pressure regulator -V.A.G 1310 A-
♦ Adapter M10 -V.A.G 1310/6-

6.5.1 Test prerequisites:

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

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Carry out the following work:

Checking
– Remove bleeder valve at one of front brake calipers.
– Connect pressure gauge -V.A.G 1310 A- and bleed.
– Apply pressure to brake pedal until gauge indicates a pressure
of 50 bar. The pressure must not drop by more than 4 bar
within the test period of 45 seconds. Renew brake master cyl‐
inder if drop in pressure exceeds specification.

96 Rep. gr.47 - Brakes - hydraulics