mK5 Jetta brakes

Front brake caliper, servicing

Volkswagen Golf 5 2004-> (A5)

Page Page 1 / 11 11 VW Rabbit GTI 2006->

Front brake caliper, servici servici ng Brake caliper FN 3, 3, servicin g 

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When carrying out repairs, install all parts supplied in repair kit. Only use mineral spirits to clean brake parts. Apply thin coat of assembly paste paste G 052 150 A2 to brake cylinders, pistons and seals.

1 - Dust cap 

Install onto bleeder bleeder valve

2 - B leeder valv e, 10 Nm


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Apply a thin coat of assembly paste G 052 150 A2 to the threads before before screwing in.

3 - Caps 

Insert into bushing

4 - Guide Guid e pins , 30 30 Nm Nm 5 - Bus hing 

Insert in brake caliper

6 - Brake caliper 7 - Brake carrier 

Bolt to brake brake caliper

8 - Retaining spring 

Insert with both ends in holes of brake brake caliper

9 - Sealing Sealing ri ng 

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

10 - Piston 

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Removing and installing 47-1, Brake caliper FN 3 piston, removing and installing Apply thin coat of assembly paste paste G 052 150 A2 to piston before inserting

11 - Protectiv e cap cap 

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Removing and installing 47-1, Brake caliper FN 3 piston, removing and installing Do not damage when inserting piston

Brake calip calip er FN FN 3 pist on, removing and inst alling Special tools, testers and auxiliary items required

Page Page 2 / 11 11


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Disassembly wedge 3409

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Piston resetting tool T 10145

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Assembly device for protective protective cap T 10146/6

Removing

- Force piston from brake caliper using using compressed air.

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Set Set a piece of wood into t he valley, valley, so that the pisto n is not d amaged. amaged.

- Remove protective cap cap from brake caliper using Trim Removal Wedge 3409 .

- Remove seal using Trim Removal Removal Wedge 3409 . When removing make sure that the surface of the cylinder is not damaged. Installing

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

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- Thinly coat piston and seal with assembly paste G 052 150 A2 before inserting. - Install sealing ring in brake caliper.

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

- Press protective cap with assembly tool - 1 - and piston resetting tool - 2 - into brake caliper so that it contacts the brake caliper all around. Check s eating of protective caps:

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

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- Press piston lightly against the protective cap and lock it into position, e.g. with trim removal wedge - 2 - . Do not angle pisto n, to avoid damaging th e seal sleeve. - Blow protective cap on with pressurized air (max. 3 bar) 1 - . Protective cap springs on to piston.

- Press piston into brake caliper using piston resetting tool -1- . The outer seal lip of the protective cap thereby slips into the groove on the piston. Brake caliper FNR-G, servicin g 

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When carrying out repairs, install all parts supplied in repair kit. Only use mineral spirits to clean brake parts. Apply thin coat of assembly paste G 052 150 A2 to brake cylinders, pistons and seals.

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1 - Dust cap 

Install onto bleeder valve

2 - Bleeder valve, 12 Nm 

Apply a thin coat of assembly paste G 052 150 A2 to the threads before screwing in.

3 - Caps 

Insert into bushing

4 - Guide pins, 30 Nm 5 - Bus hing 

Insert in brake caliper

6 - Brake caliper 

Must not be bolted apart

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7 - Brake carrier 

Bolt to brake caliper

8 - Retaining spring 

Insert in brake pad retaining spring and press below brake carrier

9 - Sealing ri ng 

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

10 - Piston 

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Removing and installing 47-1, Brake caliper FNR-G piston, removing and installing Apply thin coat of assembly paste G 052 150 A2 to piston before inserting

11 - Protectiv e cap 

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Removing and installing 47-1, Brake caliper FNR-G piston, removing and installing Do not damage when inserting piston

Brake calip er FNR-G piston, removi ng and inst alling Special tools, testers and auxiliary items required

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Disassembly wedge 3409

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Piston resetting tool T 10145

Assembly device for protective cap T 10146/6

Removing

- Force piston from brake caliper using compressed air.

Set a piece of wood into t he valley, so that the pisto n is not d amaged. - Remove protective cap from brake caliper using Trim Removal Wedge 3409 .

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- Remove seal using Trim Removal Wedge 3409 . When removing, make sure that the surface of cylinder is not damaged. Installing

- The surface of the piston and seal must only be cleaned with mineral spirits and then dried. - Thinly coat piston and seal with assembly paste G 052 150 A2 before inserting.

- Install sealing ring in brake caliper.

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

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- Press protective cap using assembly tool - 1 - and piston resetting tool - 2 - into brake caliper so that it contacts the brake caliper all around. Check s eating of protective caps: - Protective cap must no longer be able to be pulled from brake caliper by hand.

- Lightly press piston against protective cap with an extension and ratchet adapter - 1 - and hold it there, in that position. Do not angle pisto n, to avoid damaging th e seal sleeve. - Blow protective cap on with pressurized air (max. 3 bar) 2 - . Protective cap springs on to piston. - Press piston with hand into brake caliper, possibly push back slightly with piston resetting tool. The outer seal lip of protective cap slips into groove on piston.

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Rear brake caliper, servicing

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47 - 2

Rear brake caliper, servicing 

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When carrying out repairs, install all parts supplied in repair kit. Only use mineral spirits to clean brake parts. New brake calipers are filled with brake fluid and pre-bled. Apply thin coat of assembly paste G 052 150 A2 to brake cylinders, pistons and seals. When carrying out repairs it is essential to appropriately pre-bleed the brake calipers (without brake pads) before installing in the vehicle 47-2, Pre-bleeding brake caliper .

CII 41 brake assembl y o verview: 15 inch from KW 32/04


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Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru огромный архив документации по автомобилям Volkswagen, Skoda, Seat, Audi

1 - Brake calip er with parki ng brake cable lever 

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Replace brake caliper if leaking at parking brake cable lever Pre-bleed brake caliper after repairing 47-2, Pre-bleeding brake caliper

2 - Dust cap 3 - Bleeder valve, 10 Nm 

Apply a thin coat of assembly paste G 052 150 A2 to the threads before screwing in.

4 - Hex bolt, self-loc king , 35 Nm 

Replace

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When loosening and tightening


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counter hold on guide pin 5 - Guide pin with st epping 

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Shorter than item 6 Grease before pulling on protective cap

6 - Guide pins 

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Longer than item 5 Grease before pulling on protective cap

7 - Protecti ve cap 

Pull onto brake carrier and guide pin

8 - Brake pad with damper 

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Supplied as replacement part assembled with sufficient grease on guide pins If protective caps or guide pins are damaged use repair kit. Use supplied grease packet to lubricate guide pins.

9 - Protecti ve cap 

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Pull outer sealing lip onto piston Removing and installing Removing

47-2,

10 - Piston with automatic adjustment 

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Removing and installing Removing

47-2,

Apply thin coat of assembly paste G 052 150 A2 to piston before inserting

11 - Sealing ri ng 

Removing and installing Removing

Removing

47-2,


Special tools, testers and auxiliary items required

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Resetting Extracting Tool T10165

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Trim Removal Wedge 3409

- Remove piston from brake caliper by turning knurled wheel toward left.

Insert reset and remove tool so that collar makes contact on piston. 

If the piston is difficult to move, use a 13 mm open end wrench on the flats - arrow A - provided for this

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purpose.

- Remove seal using Trim Removal Wedge 3409 . Installing

- The surface of the piston and seal must only be cleaned with mineral spirits and then dried. - Thinly coat piston and seal with assembly paste G 052 150 A2 before inserting.

- Place protective seal with outer sealing lip on the piston. - Insert inner sealing lip in cylinder groove with assembly wedge 3409.

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Hold piston in front of brake caliper for this procedure. - Screw piston into housing by turning knurled wheel clockwise.

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

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Insert reset and screw out tool so that collar makes contact on brake caliper. The automatic adjustment in brake caliper is destroyed when piston is moved with piston resetting tool (e.g. T 10145) or foot brake is operated.

Pre-bleeding brake caliper

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- Open bleeder valve - arrow A - and fill with brake fluid using standard bleeder bottle until brake fluid flows out of threaded hole (end of brake hose) - arrow B - without bubbles. Close bleeder valve. Position brake caliper as illustrated to pre-bleed.

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Pressure leak test

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47 - 3

Pressure leak test

Special tools, testers and auxiliary items required 

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

Adapter M 10 V.A.G 1310/6

Test condi tions:

Brake system (hydraulic unit, brake hoses, brake lines and brake calipers) operating properly and free of leaks. - Remove bleeder valve at one front brake caliper. Connect Brake Pressure Gauge 0-250 Bar VAG1310A 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 during test period of 45 seconds. Replace master cylinder if pressure drops greatly.

Bleeding braking system

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47 - 4

Bleeding braking system Descripti on cov ers bleeding of br ake system using the brake fill er and bleeder tool VAS 5234 and V.A.G 1869 . Note: 

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Bleeding the braking system on vehicles with ABS is carried out as for vehicles with conventional braking systems. Only use new brake fluid conforming to US standard FMVSS 116 DOT 4. Genuine VW/Audi brake fluid conforms to this specification. 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 always be stored in air tight containers. Rinse off spillages, by using plenty of water.

There must b e a posi tiv e pressure of 2 bar to bleed the hydraulic unit. Brake system, bleeding usin g brake fill er and bleeder tool VAS 5234 Special tools, testers and auxiliary items required


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Brake filler/bleeder unit VAS 5234 Brake filler/bleeder unit suction adapter V.A.G 1869/4

Note: 

On vehicles with EDL, EDL/ASR or EDL/ASR/ESP, the brake system must be pre-bled when a chamber in the brake fluid reservoir is completely empty (e.g. brake system leaking).

- Remove rear wheels. Pre-bleed:

- Connect Brake filler/bleeder unit VAS 5234 . Bleeding sequence: 1 - Bleed left front and right front brake caliper together simultaneously 2 - Bleed left rear and right rear brake caliper together simultaneously - With bleeder bottle hoses attached, leave bleeder valves open long enough that brake fluid exits without bubbles. The hydraulic unit must be bled again with tester VAS 5051 via function "Basic settings" . Initiate basic setting (to bleed brake system): VAS 5051 , connecting and selecting functions 45-3, Connecting Vehicle Diagnostic, Testing and Information System VAS 5051 and selecting functions . - Then bleed brake system

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Bleeding (normal):

Ad her e st ri ct ly to wo rk seq uence w hen bl eedi ng br ake system. - Connect Brake filler/bleeder unit VAS 5234 . - Open bleeder valves in prescribed sequence and bleed brake caliper. 1 - Left front brake caliper 2 - Right front brake caliper 3 - Left rear brake caliper 4 - Right rear brake caliper Use suit able bleeder hose. It mus t fit t ight ly on bl eeder valve so that no air c an enter brake syst em. - With bleeder bottle hose attached, leave bleeder valve open long enough that brake fluid exits without bubbles. Subsequent bleeding

A second technician is required to assist: - Depress brake pedal forcefully and hold. - Open bleeder valve at brake caliper. - Press brake pedal down onto stop. - Close bleeder valve with pedal held down. - Release brake pedal slowly. This bleeding procedure must be performed 5 times per brake caliper. Bleeding sequence: 1 - Left front brake caliper 2 - Right front brake caliper 3 - Left rear brake caliper 4 - Right rear brake caliper A r oad tes t mu st be p erf or med aft er b leedi ng . Dur in g this, at least one ABS regulation must be performed! - Install rear wheels. Torque specification for wheel bolts

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Repair Manual, Suspension, Wheels, Steering, Repair Group 44, Torque specifications for wheel bolts . Changin g br ake fluid (every 2 years) Changing br ake flui d

Repair Manual, Maintenance

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Brake booster/brake master cylinder, assembly overview

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47 - 5

Brake booster/brake master cyl inder, assembly overview Note: 

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

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Pedal assembl y

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Hex nu t, self-loc king , 25 Nm 

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Replace each time

Gasket 

For brake booster


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Brake booster 

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On gasoline engines the vacuum required is taken from the intake manifold. Some vehicles with gasoline engine and automatic transmission are equipped with a Brake System Vacuum Pump V192 475, Brake system vacuum pump V192 . On vehicles with HBV, a vacuum sensor is installed 45-8, Brake Booster Vacuum Sensor G483 , removing and installing Functional check:

- With engine switched off, depress brake pedal firmly several times (to exhaust the vacuum in the unit). - Depress brake pedal with average foot pressure, hold and start engine. If booster unit is working properly, the pedal will be felt to give slightly under foot (booster assist becomes effective). 

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If faulty, replace completely. Removing and installing 47-7, Brake booster, removing and installing

Sealing ring Brake Booster Vacuum Sensor G483 

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Only on vehicles with HBV Removing and installing 45-8, Brake Booster Vacuum Sensor G483 , removing and installing

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Brake master cylinder wit hout brake light swit ch 

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Cannot be repaired. If faulty, replace completely. Removing and installing 47-6, Brake master cylinder, removing and installing

Brake master cyli nder with brake light switch 

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Application Electronic Parts Catalog (ETKA)

Application Electronic Parts Catalog (ETKA) Cannot be repaired. If faulty, replace completely. Removing and installing 47-6, Brake master cylinder, removing and installing

Brake light switch F 

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Includes Brake Pedal Switch F47 On vehicles before KW 45/05, Brake Light Switch F is located on brake pedal 46-4, Brake pedal, assembly overview Removing and installing 46-4, Brake pedal, assembly overview

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Inner Torx bol t, 5 Nm

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Heat shi eld

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Hex nu t, self-loc king , 25 Nm 

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Replace each time it is removed

Brake line, 14 Nm

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Brake line, 14 Nm 

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Brake master cylinder/secondary piston circuit to hydraulic unit

Brake master cylinder/primary piston circuit to hydraulic unit

Sealing plug 

Moisten with brake fluid and press into brake fluid reservoir

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Brake fluid reservoir

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Cap

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Sealing plug 

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Connection for vacuum hose

Vacuum h ose 

Insert into brake booster

Check-valve, checkin g

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The check valve - A - must allow air through in direction of - arrow - . Check-valve must remain closed for opposite direction.

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Observe correct installation position! Brake system vacuum pump V192

Component location of Brake System Vacuum Pump V192 is located on automatic transmission at front in direction of travel. Servicing work on brake system vacuum pump V192 is not possible. If there is a malfunction, replace Brake System Vacuum Pump V192 . Can be checked in "Guided Fault Finding" using VAS 5051 Removing

- Disconnect vacuum hose - 1 - from Brake System Vacuum Pump V192 . - Disconnect harness connector - 2 - for Brake System Vacuum Pump V192 . - Remove remaining harness connectors and wires from bracket - 3 - . - Remove - arrows - bracket - 3 - with Brake System Vacuum Pump V192 .

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

Installation is in reverse order of removal. Torque specifications: Brake System Vacuum Pump V192 to bracket

8 Nm

Bracket to automatic transmission

25 Nm

Brake Light Swit ch F from KW 45/05, removi ng and installing

On vehicles before KW 45/05, brake light switch was located on brake pedal. Removing - Remove engine cover. - On some vehicles, intake hose must be removed.

- Disconnect connector - 1 - from Brake Light Switch F . - Remove bolt - 2 - from brake master cylinder. - Pull Brake Light Switch F - 3 - downward and off from


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the brake master cylinder and remove it from the retaining tab at the top - 4 - . Installing - Installation is in reverse order of removal. Tightening torque: Torx bolt to brake master cylinder

5 Nm

Brake master cylinder, removing and installing

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47 - 6

Brake master cylind er, removing and in stallin g


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Hose clamps up to 25 mm dia. 3094 Torque wrench V.A.G 1331 Brake filler/bleeder unit V.A.G 1869 Brake filler/bleeder unit suction adapter V.A.G 1869/4


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Brake filler/bleeder unit VAS 5234

Removing

- Note or request radio code on vehicles with coded radio if necessary. - Disconnect battery.

Repair Manual, Electrical Equipment, Repair Group 27, Batteries, disconnecting and connecting - Battery, removing and installing.

Repair Manual, Electrical Equipment, Repair Group 27, Batteries, removing and installing . - Remove battery carrier. - Place sufficient lint-free cloths in area of engine and transmission. - Extract as much brake fluid as possible from brake fluid reservoir using Brake filler/bleeder unit VAS 5234 or extraction device V.A.G 1869/4 . For vehicles with manual transmissi on: - Disconnect clutch master cylinder supply hose - B using Hose Clamps Up to 25 mm dia. 3094 .

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

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Continued for all vehicles: - Disconnect connector - A - from floating warning indicator sensor. - Disconnect connector from Brake Light Switch F (only on vehicles from KW 45/05).

- Remove brake fluid reservoir. To do this press locking tabs on the reservoir outward and simultaneously pull brake fluid reservoir out of sealing plugs. - Unfasten brake lines - 1 - at brake master cylinder and plug brake lines with sealing plugs from repair kit Part No. 1H0 698 311 A. - Remove nuts - 2 - from main brake cylinder. - If present, remove heat shield. - Carefully take brake master cylinder out of brake booster. Installing

- Installation is in reverse order of removal. Observe the following points when installing: - When installing together the brake master cylinder and brake booster, make sure that the push rod is correctly located in the brake master cylinder. - Bleed braking system

47-4, Bleeding braking system

Torque specifications: Master brake cylinder at brake booster 

25 Nm

Use new nuts!

Brake lines to main brake cylinder

14 Nm

Brake booster, removing and installing

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47 - 7

Brake boos ter, removing and ins talling


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Hose clamps up to 25 mm dia. 3094 Torque wrench V.A.G 1331 Brake filler/bleeder unit V.A.G 1869 Brake filler/bleeder unit suction adapter V.A.G 1869/4


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Removing

- Note or request radio code on vehicles with coded radio if necessary. - Disconnect battery.

Repair Manual, Electrical Equipment, Repair Group 27, Batteries, disconnecting and connecting - Battery, removing and installing.

Repair Manual, Electrical Equipment, Repair Group 27, Batteries, removing and installing . - Remove battery carrier. - Place sufficient lint-free cloths in area of the engine and transmission. - Extract as much brake fluid as possible from brake fluid reservoir using Brake filler/bleeder unit VAS 5234 or extraction device V.A.G 1869/4 . For vehicles with manual transmissi on: - Disconnect clutch master cylinder supply hose - B using Hose Clamps Up to 25 mm dia. 3094 .

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

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Continued for all vehicles: - Disconnect connector - A - from floating warning indicator sensor. - Disconnect connector from Brake Light Switch F (only on vehicles from KW 45/05).

- Remove brake fluid reservoir. To do this press locking tabs on reservoir outward and simultaneously pull brake fluid reservoir out of sealing plugs. - Unfasten brake lines - 1 - at brake master cylinder and plug brake lines with sealing plugs from repair kit Part No. 1H0 698 311 A. - Remove nuts - 2 - from brake master cylinder. - If present, remove heat shield. - Carefully take brake master cylinder out of brake booster. - Pull vacuum hose out of brake booster. For vehicles with manual transmissi on:

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

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Repair Manual, Manual Transmission, Repair Group 34, Selector mechanism, servicing Continued for all vehicles: - Remove trim on drivers side.

Repair Manual, Body Interior, Repair Group 70, Instrument panel Brake light switch is no longer present on mounting bracket from KW 45/05.

- Disconnect connector - 1 - from brake light switch. - Remove Brake Light Switch - 2 - by rotating 45 left.

toward

- Remove air channel - 3 - . - Remove cover - 4 - . - Disconnect brake pedal from brake booster Separating brake pedal from brake booster .

46-4,


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- Remove nuts - 1 - from brake booster. - Loosen both upper nuts - 2 - from mounting bracket. - Carefully remove brake booster from vehicle. Installing

- Installation is in reverse order of removal. Observe the following when installing: - Clip brake pedal together with brake booster 4 - After installing, bleed brakes system and clutch.

Topic 46-

47-4, Bleeding braking

Only on vehicles up to KW 45/05: - Adjust brake light switch 46-4, Brake light switch F up to KW 45/05, removing, installing and adjusting . Torque specifications: Brake booster to foot pedal assembly/cross panel 

Use new nuts!

Master brake cylinder at brake booster 

25 Nm

25 Nm

Use new nuts!

Brake lines to main brake cylinder

14 Nm

Brake line repairs

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47 - 8

Brake line repairs Flare brake lines with 5 mm outer diameter using brake line flaring appliance VAS 6056 without damaging coating. In this way, brake lines can be inexpensively partially replaced in certain cases. Work with brake line kit V.A.B. 1356 is not permitted because of the coating and diameter of black brake lines. Note: 

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Brake lines must not be bent more than 90 , otherwise they kink or deform causes unacceptable constriction in the line. Disconnect brake lines preferably at vehicle floor. Position of intermediate pieces should be selected so that they cannot rub against moving parts. Do not lubricate spindle, clean only with mineral spirits.

Special tools, testers and auxiliary items required

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Brake line flaring appliance VAS 6056

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Brake line repairs

Listing of individual tools: 

Flaring appliance VAS 6056/1 

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Tube cutter VAS 6056/2 Brake line shearin g too l VAS 6056/3 

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flaring jaws VAS 6056/6 are contained in the flaring appliance VAS 6056/1

The threaded pins (in shaft and at sides) are set and must not be adjusted!

Self-grip pl iers with pl astic clampi ng j aws VAS 6056/4

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Brake line repairs

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Line bendin g too l VAS 6056/5

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SW6 angle screwdr iver

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Flaring jaws VAS 6056/7

Flaring tool, assembly overview

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Upper part of flaring t ool 

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Hand grip mount 

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Remove to change flaring jaws

Must be removed to reach retaining screw for upper part

Retaining screw

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Brake line repairs

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For upper part of flaring tool

Flaring jaws threaded pins 

Center and hold flaring jaws

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2 mm hex socket head

Flaring jaws 

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Various Assembly instructions 478, Flaring jaws assembly instructions:

Flaring jaws assembly instructions:

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VAS 6056/6 (dark) for black brake lines

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VAS 6056/7 (light) for green brake lines

Note: 

The arrow on the rounded side of the flaring jaws must face toward edge of housing and the straight side of the flaring jaws must be installed toward spindle, otherwise flared head will not be formed correctly.

Instructions

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Brake line repairs

- Remove affected brake line at brake caliper or wheel brake cylinder and collect escaping brake fluid and dispose of it correctly.

- Disconnect brake line at appropriate location (straight, accessible part) with line cutter - 2 - . - Remove piece to be exchanged. - Lubricate brake line surface.

- Clamp brake line in self-grip pliers - 4 - so that 50 mm of the plastic clamping jaws show. - Clamp shearing tool - 3 - in a drill and place it on brake line. - Shear coating from brake line at a slow drill RPM and with light pressure against the line. The length of the sheared-off portion is determined by the stop in the shearing tool. - Remove shearing tool from brake line and remove shearing remains.

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Brake line repairs

- Remove self-grip pliers and tube fitting - D - from brake line.

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

Brake line must contact stop when hex socket heat screws are tightened, otherwise flared head will not be formed correctly.

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

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mK5 Jetta brakes

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