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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

polycarbamide grease -

G 052 142 A2- .

❑ 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 - Drive shaft

6.1

Removing and installing speed sensor

on front axle

6.1.1

Removing

– Raise vehicle.

Touareg 2010 ➤

Brake systems - Edition 05.2011

6. Removing and installing parts of ABS system on front and rear axle    

23

Содержание Touareg 2010

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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