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G.

15 - Brake pedal position sender -G100- retainer

❑ Only with hybrid models.
❑ Adjusting 

⇒ page 64

 .

16 - Bolt, 3 Nm

❑ Only with hybrid models.

17 - Retaining ring

❑ For pivot pin.

5.1

Separating brake pedal from brake ser‐

vo

Special tools and workshop equipment required
♦ Release tool -T10159 A-

– Remove footwell cover ⇒  General body repairs, interior; Rep.

gr.  68 ; Compartments, covers and trims .

– First press brake pedal in direction of brake servo and hold.
1 - Brake pedal
2 - Plunger rod
3 - Retaining lugs
– Insert release tool -T 10159- and pull in direction of driver seat.

When doing this, counterhold on brake pedal (at this stage,

brake 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 -T 10159- and brake pedal together towards

driver seat. (This action will pull the brake pedal off the ball

head of the plunger rod).

Touareg 2010 ➤

Brake systems - Edition 05.2011

62

     Rep. gr.46 - Brakes - mechanism

Summary of Contents for Touareg 2010

Page 1: ...e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d...

Page 2: ...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 Technic...

Page 3: ...of ABS system on front and rear axle 23 6 1 Removing and installing speed sensor on front axle 23 6 2 Removing and installing parts of ABS system on rear axle 24 6 3 Removing and installing speed sen...

Page 4: ...tem 75 4 1 Bleeding brake system with brake filling and bleeding equipment VAS 5234 75 4 2 Changing brake fluid 77 5 Assembly overview brake servo brake master cylinder 78 5 1 Removing and installing...

Page 5: ...rakes 1KJ Arrow 2 Front brakes 1LG The vehicle data sticker can be found in the spare wheel well and in the service booklet The following table explains the PR numbers These are impor tant for combini...

Page 6: ...m i t t e d u n l e ssauthorisedbyVolkswagenAG VolkswagenAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h...

Page 7: ...servo Brake master cylinder in mm 26 99 Brake servo in inches 9 10 tandem 2 2 Front brakes 2 2 1 Front brake Brembo 17 Item PR No 1LC 1LE 1 Brake caliper Brembo 17 2 Brake lining thickness mm 10 5 Br...

Page 8: ...i g h t b y V o l k s w a g e n A G 2 3 Rear brakes 2 3 1 Rear brakes 17 brake disc Item PR No 1KJ 1KQ 1 Brake caliper Brembo 17 2 Brake lining thickness mm 10 Brake pad wear limit without backplate m...

Page 9: ...s authorised by Volkswagen fulfil these requirements 3 3 Testing vehicles with electric differential lock The brake test must be performed on a regulated contra rotating roller brake test stand Contra...

Page 10: ...t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Entering T V mode is indicated by the yellow electric parking brake and...

Page 11: ...d rear The servo as sistance is effected pneumatically by the vacuum brake servo unit Faults in the ABS influence the brake system and servo assis tance A change in braking behaviour is to be reckoned...

Page 12: ...which the brake system had to be opened bleed the brake system with brake filling and bleeding equipment VAS 5234 page 75 During the final road test ensure that a controlled brake test is performed at...

Page 13: ...i g h t b y V o l k s w a g e n A G 3 Connecting VAS 5051 and select ing functions Special tools and workshop equipment required VAS 5051 Vehicle Diagnosis Testing and Information Sys tem Diagnosis c...

Page 14: ...odes 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 int...

Page 15: ...f the components 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 Brake pressure sender G201 3 Brake p...

Page 16: ...lateral acceleration sender G200 yaw rate sender G202 and longitudinal acceleration sender G251 Combined in one housing Observe installation instructions page 26 12 Diagnostic connection Location Dri...

Page 17: ...lectronic Parts Catalogue ET KA 5 Bolt 9 Nm 6 Rubber damper 7 Brake line 18 Nm From secondary piston circuit of brake master cylinder to hydraulic unit Identification 8 5 mm and union nut with thread...

Page 18: ...primary piston circuit of brake master cylinder Identification 8 5 mm and union nut with thread M12 x 1 B From hydraulic unit to secondary piston circuit of brake master cylinder Identification 8 5 m...

Page 19: ...i g h t b y V o l k s w a g e n A G Removing Note or request radio code on vehicles with coded radio if necessary Disconnect battery Electrical system Rep gr 27 Discon necting and reconnecting battery...

Page 20: ...for all vehicles Remove bolts arrows on coolant expansion tank 1 Slide coolant expansion tank 1 in direction of arrow out of retainer Place coolant expansion tank 1 to one side Note Do not pull off c...

Page 21: ...damaged hydraulic unit must be renewed Severe shocks e g dropping impact may destroy control unit Control unit must not then be used Installing Note Use new bolts A new control unit may be mounted on...

Page 22: ...hydraulic unit Special tools and work shop equipment re quired Torque wrench V A G 1410 Brake pedal depres sor V A G 1869 2 Sealing plugs repair kit Part No 1H0 698 311 A The transport protection for...

Page 23: ...r i g h t b y V o l k s w a g e n A G WARNING Do not bend the brake lines in the area of the hydraulic unit 5 1 3 Removing control unit and hydraulic unit Note or request radio code on vehicles with...

Page 24: ...e 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...

Page 25: ...roy control unit Control unit must not then be used Clean surfaces before assembling Note Use new bolts A new control unit may be mounted on an existing hydraulic unit max twice to guarantee impermeab...

Page 26: ...d out of bracket when installing After installing check hydraulic unit with con trol unit for proper seating otherwise malfunctions can occur Remove brake pedal depressor V A G 1869 2 Bleed brake syst...

Page 27: ...r i g h t b y V o l k s w a g e n A G 6 Removing and installing parts of ABS system on front and rear axle 1 ABS speed sensor Before inserting sensor clean fitting hole inner surface and coat with po...

Page 28: ...ull ABS speed sensor out of wheel bearing housing 6 1 2 Installing Before inserting speed sensor clean hole inner surface and coat speed sensor all round with polycarbamide grease G 052 142 A2 Insert...

Page 29: ...moving Raise vehicle Remove wheel Remove brake caliper and secure with wire so that weight of brake caliper does not strain or damage brake hose Separate connector 1 from speed sensor wire and from sp...

Page 30: ...udinal ac celeration sender G251 7 1 1 Removing Location behind selector mechanism under centre console from driver s perspective Remove gearshift trim General body repairs interior Rep gr 68 Compartm...

Page 31: ...s bracket and is free of stress Do not use the securing nuts to forcibly position ESP sensor unit Tighten securing nuts to 8 Nm Carry out basic settings for lateral acceleration sender G200 and longit...

Page 32: ...ter work for which the brake system had to be opened bleed the brake system with brake filling and bleeding unit VAS 5234 or extraction unit V A G 1869 4 Fit brake pedal depressor V A G 1869 2 before...

Page 33: ...termined limit approx 4 mm the warning lamp in the dash panel insert comes on Checking thickness Maintenance Booklet Front and rear brake discs and pads linings Checking condition of discs and thickne...

Page 34: ...g 1 Remove retaining spring Before pressing back brake pads draw off brake fluid from res ervoir Otherwise particularly if reservoir has been topped up fluid will overflow and cause damage Push brake...

Page 35: ...g h t b y V o l k s w a g e n A G ularly if reservoir has been topped up fluid will overflow and cause damage Press pistons back Carefully insert sensors of brake pad wear indicator wire into new bra...

Page 36: ...bracket on wheel bearing housing Secure brake wear indicator wire on bleed valve with the dust cap 2 Fit wheels Specified torque of wheel bolts Running gear axles steering Rep gr 44 Specified torques...

Page 37: ...nect brake line from brake caliper Disconnect bracket Item 16 page 29 from wheel bearing housing Remove brake pads page 29 Unbolt brake caliper from wheel bearing housing 1 3 2 Installing Bolt brake c...

Page 38: ...extraction unit V A G 1869 4 Fit brake pedal depressor V A G 1869 2 before removing a brake caliper or disconnecting a brake hose release pressure in system 1 Brake disc Ventilated brake disc 368 mm B...

Page 39: ...With break pad wear indicator When wear reaches a predetermined limit approx 4 mm the warning lamp in the dash panel insert comes on Checking thickness Maintenance Booklet Front and rear brake discs...

Page 40: ...ion when installing or braking will be uneven Remove wheels Remove upper retainer for brake hose 1 from wheel bearing housing arrow Disconnect brake pad wear indicator connector 1 and pull connector o...

Page 41: ...is Then push brake caliper forwards movement arrow until cal iper engages in recesses arrows of assembly pins T10439 Lever brake pads out of brake caliper arrows using a com mercially available screwd...

Page 42: ...reservoir Otherwise partic ularly if reservoir has been topped up fluid will overflow and cause damage Press pistons back The retaining springs are correctly seated in the brake caliper Fit brake pad...

Page 43: ...d sensor Fit wheels Specified torque of wheel bolts Running gear axles steering Rep gr 44 Specified torques of wheel bolts Note Every time after changing pads depress brake pedal firmly several times...

Page 44: ...eeder bottle Separate connector for brake pad wear indicator Disconnect brake hose from brake caliper Unbolt brake caliper from wheel bearing housing Remove brake pads page 35 1 6 2 Installing Install...

Page 45: ...genAGdoesnot guaranteeorac c e p t a n y l i a b i l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w...

Page 46: ...2 before removing a brake caliper or disconnecting a brake hose release pressure in system 1 Brake disc drum Ventilated brake disc 330 mm Brake disc thickness 28 mm Wear limit 26 mm Brake drum 210 mm...

Page 47: ...Do not disconnect brake line when changing brake pads or brake disc 14 Bolt 10 Nm 15 Bracket 16 Wheel bearing housing Repairing thread in wheel bearing housing member page 52 17 Brake carrier plate T...

Page 48: ...G 1332 Piston resetting appliance T10145 2 2 1 Removing Note Mark brake pads linings when removing if they are to be reused Fit in same position when installing or braking will be uneven Remove rear...

Page 49: ...be used again Cleaning WARNING Do not blow out brake system with compressed air the result ing dust constitutes a health hazard Clean brake caliper Use only methylated spirits for cleaning the brake...

Page 50: ...l bolts Note Every time after changing pads depress brake pedal firmly several times with vehicle stationary so that brake pads are properly seated in their normal operating position Check brake fluid...

Page 51: ...g Install brake pads page 44 Bolt brake caliper to wheel bearing housing Reconnect brake line to brake caliper Push brake pad wear indicator wire into recess in brake cali per Reconnect brake wear ind...

Page 52: ...en Remove rear wheels Connecting VAS 5051 and selecting functions page 9 Do do this select electromechanical parking brake and mov ing parking brake motor to assembly position function Use VAS 5051 to...

Page 53: ...of brake shoe web 1 and parking brake motor mounting 2 WARNING Ensure that no grease gets on friction surfaces of brakes shoes and brake drum Then perform basic setting of electromechanical parking br...

Page 54: ...p lies outside tolerance carry out following procedures Unscrew sealing plug arrow for parking brake adjustment nut Insert a screwdriver through the hole in the brake disc and turn the adjustment nut...

Page 55: ...s w a g e n A G Right adjustment nut Turning in arrow direction A reduces air gap tightens Turning in arrow direction B increases air gap loosens Arrow C shows the direction of travel forwards After...

Page 56: ...Fitted bolt M14x1 5 4 1 Brass sleeve M12 for special drill bit and seat milling cutter 4 2 Brass sleeve M12 for screw tap 5 1 Brass sleeve M14 for special drill bit and seat milling cutter 5 2 Brass s...

Page 57: ...disc Unscrew brake caliper from wheel bearing housing Remove brake caliper and secure with wire so that weight of brake caliper does not strain or damage brake hose Use VAS 5051 to move parking brake...

Page 58: ...e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Manually drill until gripping tool 1 touches brass sleeve 3 arrow A Loosen fitted bol...

Page 59: ...seat A first into countersink Seat of insert must disappear fully inside countersink Remove swarf wear safety goggles Swing drilling jig 1 back over bore and fasten with fitted bolt 2 Then slide appr...

Page 60: ...onto the driving tool because the insert would otherwise be prematurely deformed Screw insert 1 in manually using driving tool 2 until it is flush with wheel bearing housing A The driving tool 2 must...

Page 61: ...in centre con sole 4 Warning lamp with 2 func tions Electromechanical parking brake warning lamp K213 lights up red Auto hold warning lamp K237 lights up green Additionally in central display in dash...

Page 62: ...t for electromechanical parking brake J540 may then no longer be used Removing Switch off ignition and all electrical consumers and remove ignition key Remove right side panel in luggage compartment G...

Page 63: ...electing functions page 9 Do do this select electromechanical parking brake and mov ing parking brake motor to assembly position function Use VAS 5051 to move parking brake motors to assembly position...

Page 64: ...g h t b y V o l k s w a g e n A G Secure parking brake motor mounting with cable tie 2 to pre vent it turning Unscrew brake carrier plate Release and disconnect connector 1 on parking brake motor Rem...

Page 65: ...earing and contact surfaces with grease G 000 450 02 1 Pedal cluster mounting bracket 2 Bolt 20 Nm 3 Support 4 Bolt 3 Nm 5 Pivot pin Only fits in one position recess in pivot pin to lug on mounting br...

Page 66: ...tools and workshop equipment required Release tool T10159 A Remove footwell cover General body repairs interior Rep gr 68 Compartments covers and trims First press brake pedal in direction of brake s...

Page 67: ...Rep gr 68 Compartments covers and trims Left hand drive LHD Remove left dash panel cover driver side General body re pairs interior Rep gr 68 Compartments covers and trims Remove right dash panel cove...

Page 68: ...dal 5 2 2 Installing Install in reverse order Note Pivot pin fits in one position only Clip brake pedal to brake servo page 63 Specified torque Component Specified torque Crash wedge to mounting brack...

Page 69: ...and bearing bracket B have slots to provide a sideways adjustment This also prevents twisting Loosen bolts 2 until retainer 1 with brake pedal position sender G100 3 can be moved back and forth in di...

Page 70: ...Push stop tab 1 in direction of arrow until stop tab engages on other side of retainer 2 Install convenience system central control unit J393 with re tainer Electrical system Rep gr 97 Control units...

Page 71: ...pplied in repair kit Use only methylated spirits for cleaning the brake Apply thin coat of assembly paste G 052 150 A2 to brake cylinder piston and seal 1 Dust cap Fit onto bleeder valve Secures brake...

Page 72: ...1 Bleeder valve 12 Nm Before screwing in ap ply thin coat of assembly paste G 052 150 A2 to thread 11 mm 2 Dust cap Fit onto bleeder valve 3 Brake caliper 4 Retaining spring 5 Piston seal Removing an...

Page 73: ...of brake caliper using com pressed air Only one piston can be pressed out at a time Hold opposing pis ton in brake caliper using piston resetting tool a Block the other pistons with for example a woo...

Page 74: ...l i t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Insert seal in brake caliper Place pr...

Page 75: ...ly methylated spirits for cleaning the brake Apply thin coat of assembly paste G 052 150 A2 to brake cylinder piston and seal 1 Dust cap Fit onto bleeder valve 2 Bleeder valve 12 Nm Before screwing in...

Page 76: ...per housing using compressed air Only one piston can be pressed out at a time When doing this hold the opposing piston in the caliper using the piston resetting appliance a Block the other pistons wit...

Page 77: ...t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Insert oil seal in brake caliper housing Place pr...

Page 78: ...ired Tester for brake pressure regulator V A G 1310 A Adapter M10 V A G 1310 6 or Adapter M8 V A G 1310 13 or Adapter M7 V A G 1310 1 Test prerequisites Brake system hydraulic unit brake hoses brake l...

Page 79: ...ing agents Mineral oils damage the seals and packings in the brake system Brake fluid is poisonous Also due to its corrosive effect brake fluid must not come into contact with paintwork Brake fluid is...

Page 80: ...ctly to work sequence when bleeding brake system Brembo brake calipers have two bleed valves Always bleed brake calipers at both bleed valves Bleed outer bleed valve first Connect brake filling and bl...

Page 81: ...occurs e g in the case of brake system leaks Subsequent bleeding requires the assistance of a second me chanic Depress brake pedal firmly and hold Open bleeder valve on brake caliper Fully depress br...

Page 82: ...3 Allocation Electronic Parts Catalogue ET KA 2 Pedal cluster mounting bracket 3 Self locking hexagon nut 23 Nm Always renew after re moving 4 Seal For brake servo 5 Brake servo On petrol engines the...

Page 83: ...13 Brake line 18 Nm Primary piston circuit of brake master cylinder to hydraulic unit page 14 14 Sealing plug Moisten with brake fluid and press into brake fluid reservoir 15 Brake fluid level warning...

Page 84: ...th E box Pull connector 2 off brake light switch F 1 Unscrew Torx bolt from brake master cylinder Pull brake light switch F 1 off top of brake master cylinder then from clip at bottom 5 1 2 Installing...

Page 85: ...t y w i t h r e s p e c t t o t h e c o r r e c t n e s s o f i n f o r m a t i o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Insert brake light switch F 1 into clip o...

Page 86: ...ply 6 1 Overview vacuum pump for brake ser vo diesel vehicles Vacuum pump for 6 cyl diesel engine Must not be dismantled Vacuum pump 2 Vacuum hose to brake servo 3 with non return valve Removing and i...

Page 87: ...e retainer 6 Bracket 7 Vent hose 8 Torx bolt 8 Nm Coolant pipe to bracket 9 Torx bolt 9 Nm Bracket to bracket 10 Clip Vent hose 11 Torx bolt 7 Nm 12 Clip with cable tie 13 Sleeve 14 Vacuum hose To vac...

Page 88: ...body repairs exterior Rep gr 50 Noise insulation Release vacuum hose A and pull off arrow Unclip wiring harness from retainer C and lay to side Release connector B from vacuum pump for brakes V192 and...

Page 89: ...Open clamp 1 and remove suction line Pull off engine compartment seal in vicinity of brake servo Remove right plenum chamber cover General body repairs exterior Rep gr 50 Plenum chamber cover Remove...

Page 90: ...ll connector off vacuum sender G608 Guide vacuum line with vacuum sender G608 out to right Remove vacuum sender G608 from vacuum line Release clip with a pair of pliers 1 Carefully lever vacuum sender...

Page 91: ...acuum 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...

Page 92: ...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 c...

Page 93: ...luence 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 ga...

Page 94: ...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 6 4 4 Vacuum generation with manual vac uum pu...

Page 95: ...r Pull off engine compartment seal in vicinity of brake servo Remove left plenum chamber bulkhead General body re pairs exterior Rep gr 50 Plenum chamber bulkhead Pull connector 2 off brake light swit...

Page 96: ...s when installing When assembling brake master cylinder with brake servo make sure plunger rod is properly positioned in brake master cylinder Sealing ring between brake master cylinder and brake serv...

Page 97: ...exterior Rep gr 50 Plenum chamber cover Remove bolts arrows for coolant expansion tank 1 Slide coolant expansion tank 1 in direction of arrow out of retainer Place coolant expansion tank 1 to one side...

Page 98: ...o n i n t h i s d o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unclip brake line 1 from retainers arrows Unscrew brake lines from brake master cylinder A and B Seal brake lines and brak...

Page 99: ...brake master cylinder 1 off brake servo 2 7 2 2 Installing Install in reverse order Note the following points When assembling brake master cylinder with brake servo make sure plunger rod is properly...

Page 100: ...rvo Remove left plenum chamber bulkhead General body re pairs exterior Rep gr 50 Plenum chamber bulkhead Pull E box out of retainer in plenum chamber and lay to side Electrical system Rep gr 97 E boxe...

Page 101: ...move footwell cover General body repairs interior Rep gr 68 Compartments covers and trims Separate brake pedal from brake servo page 62 Unscrew nuts arrows from brake servo Carefully remove brake serv...

Page 102: ...o c u m e n t C o p y r i g h t b y V o l k s w a g e n A G 8 2 Removing and installing brake servo right hand drive vehicle Special tools and workshop equipment required Release tool T10159 A Sealin...

Page 103: ...in direction of arrow out of retainer Place coolant expansion tank 1 to one side Note Do not pull off coolant hoses Remove nuts arrows and remove bracket 1 Place bracket 1 with lines to one side Remo...

Page 104: ...c u m e n t C o p y r i g h t b y V o l k s w a g e n A G Unscrew brake lines from brake master cylinder A and B Seal brake lines and brake master cylinder using sealing plugs 1H0 698 311 A from repai...

Page 105: ...ully remove brake servo from plenum chamber 8 2 2 Installing Install in reverse order Note the following points Carefully insert brake servo and tighten nuts Clip brake pedal to brake servo page 63 Wh...

Page 106: ...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...

Page 107: ...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 Assembl...

Page 108: ...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...

Page 109: ...op 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 li...

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