VW Eos 2006, Golf Mk5 2004, Golf Plus Mk5 2005, Touran 2003 Brake systems - Workshop Manual

1.2 Front brakes, Golf......Page 7
1.4 Rear brakes, Touran......Page 8
1.5 Rear brakes, front-wheel drive Golf......Page 9
1.7 Rear brakes, Eos......Page 10
2.3 Front brakes......Page 11
2.4 Rear brakes (disc brakes)......Page 13
3.3.2 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 dynamometer as follows:......Page 15
1 General notes on anti-lock brake system......Page 17
2 Notes for repair work on anti-lock brake system......Page 18
3 Connecting -VAS 5051- and selecting functions......Page 19
4.1 ABS Mark 70 (ABS/TCS)......Page 21
4.2 ABS Mark 60 (ABS/EDL/TCS/ESP)......Page 23
4.3 ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 22/2008......Page 25
4.4 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 22/2008......Page 27
5 Fault display via warning lamps......Page 29
6.1 ABS Mark 70 (ABS/TCS)......Page 32
6.1.1 Connecting brake lines from brake master cylinder to hydraulic unit......Page 33
6.1.2 Removing control unit and hydraulic unit......Page 34
6.1.3 Unbolting control unit from hydraulic unit......Page 36
6.1.4 Installing new control unit......Page 37
6.1.5 Installing control unit and hydraulic unit......Page 38
6.2 ABS Mark 60 (ABS/EDL/TCS/ESP)......Page 39
6.2.1 Connecting brake lines from brake master cylinder to hydraulic unit......Page 40
6.2.2 Removing control unit and hydraulic unit......Page 42
6.2.3 Unbolting control unit from hydraulic unit......Page 44
6.2.4 Installing new control unit......Page 45
6.2.5 Installing control unit and hydraulic unit......Page 46
6.3 ABS Mark 60 (ABS/EDL/TCS/ESP) up to week 22/2008......Page 47
6.3.1 Connecting brake lines from brake master cylinder to hydraulic unit......Page 48
6.3.2 Removing control unit and hydraulic unit......Page 50
6.3.3 Unbolting control unit from hydraulic unit......Page 52
6.3.4 Installing new control unit......Page 53
6.3.5 Installing control unit and hydraulic unit......Page 54
6.4 ABS Mark 60 (ABS/EDL/TCS/ESP) from week 22/2008......Page 55
6.4.1 Connecting brake lines from brake master cylinder to hydraulic unit......Page 56
6.4.2 Removing control unit and hydraulic unit......Page 57
6.4.3 Unbolting control unit from hydraulic unit......Page 59
6.4.5 Installing control unit and hydraulic unit......Page 60
7.1.1 Removing and installing speed sensor on front axle......Page 62
7.2 Removing and installing parts of anti-lock brake system on rear axle (front-wheel drive)......Page 63
7.3 Removing and installing parts of anti-lock brake system on rear axle (four-wheel drive)......Page 64
7.3.1 Removing and installing speed sensor on rear axle......Page 65
8.2 Removing and installing ESP sensor unit -G419- (Golf, Eos)......Page 66
8.3 Removing and installing steering angle sender -G85-......Page 67
8.4 Removing and installing brake servo vacuum sender -G483-......Page 68
1.1 Repairing front brakes, FS III brake caliper......Page 69
1.2 Removing and installing brake pads/linings......Page 70
1.2.1 Removing......Page 71
1.2.2 Installing......Page 72
1.3 Removing and installing brake caliper......Page 73
1.3.2 Installing......Page 74
1.4 Repairing front brake, FN 3 brake caliper......Page 75
1.5 Removing and installing brake pads/linings......Page 78
1.5.1 Removing......Page 79
1.5.2 Installing......Page 80
1.6.1 Removing......Page 81
1.6.2 Installing......Page 82
1.7 Repairing front brake, FNR-G brake caliper......Page 83
1.8 Removing and installing brake pads/linings......Page 84
1.8.1 Removing......Page 85
1.8.2 Installing......Page 86
1.9 Removing and installing brake caliper......Page 87
1.9.2 Installing......Page 88
2.1 Repairing rear brake CI 38......Page 90
2.2 Removing and installing brake pads/linings......Page 91
2.2.2 Installing......Page 92
2.3 Removing and installing brake caliper......Page 93
2.3.2 Installing......Page 94
2.4 Repairing rear brake CII 38......Page 95
2.5.1 Removing......Page 97
2.5.2 Installing......Page 98
2.6 Removing and installing brake caliper......Page 99
2.6.2 Installing......Page 100
2.7 Repairing rear brake CII 41......Page 101
2.8 Removing and installing brake pads/linings......Page 103
2.8.2 Installing......Page 104
2.9 Removing and installing brake caliper......Page 105
2.9.2 Installing......Page 106
2.10 Adjusting handbrake......Page 107
3.1.1 Removing......Page 109
3.1.2 Installing......Page 111
3.2.1 Removing......Page 112
3.2.2 Installing......Page 113
4.1 Separating brake pedal from brake servo......Page 115
4.2 Removing and installing brake light switch - F- from week 45 of 2005......Page 116
4.2.1 Brake light switch, old version......Page 117
4.2.2 Brake light switch, new version......Page 118
1.2 Removing and installing piston for brake caliper FS III......Page 119
1.2.2 Installing......Page 120
1.3 Repairing brake caliper FN 3......Page 121
1.4 Removing and installing piston for brake caliper FN 3......Page 122
1.4.1 Removing......Page 123
1.4.2 Installing......Page 124
1.5 Repairing FNR-G brake caliper......Page 125
1.6 Removing and installing piston for FNR-G brake caliper......Page 126
1.6.1 Removing......Page 127
1.6.2 Installing......Page 128
2 Repairing rear brake caliper......Page 130
2.1 Removing......Page 132
2.2 Installing......Page 133
2.3 Pre-bleeding brake caliper......Page 134
3.1 Test prerequisites:......Page 135
4 Bleeding brake system......Page 136
4.1.1 Pre-bleeding:......Page 137
4.2.1 Changing brake fluid......Page 138
5.1 Assembly overview - brake servo/brake master cylinder (left-hand drive vehicle)......Page 139
5.2 Assembly overview - brake servo/brake master cylinder (right-hand drive vehicle)......Page 140
5.3 Overview - exhauster pump for brake servo (diesel vehicles)......Page 142
5.6.1 Removing......Page 143
5.7 Removing and installing brake light switch -F- as of week 45/05......Page 144
6.1 Removing......Page 145
6.2 Installing......Page 146
7.1 Removing......Page 147
7.2 Installing......Page 149
8.2 Repairing brake lines......Page 150
8.2.2 Work instructions......Page 152