Servicio Sistemas de Frenos

8/3/2019 Servicio Sistemas de Frenos

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Brake

System

from m.y.1997

Brake System On Board

Diagnostic (OBD) from m.y. 1997


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6HOHFWDWRSLF00 - General, Technical data

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45 - Anti-lock brake system

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ABS system, general information

Notes for repair work on ABS, ABS/EDL systemsHydraulic unit, assembly overviewABS hydraulic control unit, removing and installing

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ABS system, general informationNotes for repair work on ABS systemsHydraulic unit, assembly overviewABS hydraulic control unit, removing and installing

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ABS system, general information

Notes for repair work on ABS systemsHydraulic unit, assembly overviewABS hydraulic control unit, removing and installing

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ABS front axle components, removing and installingABS rear axle components, removing and installing

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Sender for Rotation Rate -G202- and Sensor for transverse acceleration -G200-, removing andinstallingABS Control Module (w/EDL) -J104-, removing and installing

Steering angle sensor -G85-, removing and installing46 - Brakes - Mechanical components

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Distinguishing characteristics of front brake calipersFront brakes, servicing (Lucas C54 fist caliper, 15" wheels)Brake pads, removing and installingFront brakes, servicing (Lucas RC 54 frame caliper, 15" wheels)Brake pads, removing and installingFront brakes, servicing (FN 3 fist caliper, 15" wheels)Brake pads, removing and installingFront brakes, servicing (FN 3 fist caliper, 16" wheels)

Brake pads, removing and installingFront brakes, servicing (FNR fist caliper 16" wheels)Brake pads, removing and installing

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Brake pads, removing and installingParking brake, adjusting

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Brake pads, removing and installing

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Front parking brake cable, removing and installingPull-lever, removing and installingRear parking brake cable, removing and installing

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%UDNHSHGDODVVHPEO\RYHUYLHZBrake pedal, removing and installing

47 - Brakes - Hydraulic components

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Front brake caliper, servicing, (Lucas C54 fist caliper, 15" wheels)Front brake caliper pistons, removing and installing (Lucas C54 fist caliper, 15" wheels)Front brake caliper, servicing (Lucas RC 54 frame caliper 15" wheels)Front brake caliper pistons, removing and installing (Lucas RC 54 frame caliper, 15" wheels) Front brake caliper, servicing (FN3 fist caliper, 15" wheels)Front brake caliper pistons, removing and installing (FN 3 fist caliper, 15" wheels)Front brake caliper, servicing (FN3 fist caliper, 16" wheels)Front brake caliper pistons, removing and installing (FN 3 fist caliper, 16" wheels)Front brake caliper, servicing (FNR fist caliper, 16" wheels)Front brake caliper pistons, removing and installing (FNR fist caliper, 15" wheels)

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Rear brake caliper piston, removing and installingPressurized leak test

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Brake system, bleeding using US1116 brake bleederBrake system, bleeding without brake filler and bleeder tool

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Brake pressure regulator, adjusting

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Check-valve, checking

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Master brakecylinder

in mm 23.81

Brake booster ininches

9 4 + 84

1 Brake caliper Lucas C54

2 Brake pad,thickness

mm 13.5

3 Brake disc in mm 282

Brake disc,

thickness

mm 18

4 Brake caliper,pistons

in mm 54

1) M-number (optional equipment no.), clarificationPage 00-9

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inmm

23.81


9 4 +

8 4

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mm 13

3 Brake disc inmm

280


5/166

Brake disc,thickness(internallyvented)

mm 24


inmm

54

1) M-number (optional equipment no.),clarification Page 00-9

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inmm

25,4


9 4 +

8 4

1 Brake caliper FN 3

2 Brake pad,

thickness

mm 13.5

3 Brake disc inmm

280

Brake disc,thickness(internally vented)

mm 24


inmm

57



6/166


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Master brake

cylinder

in

mm

25,4


9 4 +

8 4

1 Brake caliper FN 3


mm 13.5

3 Brake disc inmm

300

Brake disc,

thickness(internally vented)

mm 26


inmm

57



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in mm 25,4


9 4 + 84

1 Brake caliper FNR


mm 14


Brake disc, mm 26


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thickness


in mm 57


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inmm

23.81

Brakebooster

ininches

9 4 + 8 4

1 Brake disc inmm

280

Brake disc,thickness

mm 12


mm 11.5


inmm

38



8/166


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Master brake

cylinder

in mm 25,4


9 4 + 84


Brake disc,thickness

mm 12


mm 11.5

3 Brake caliper,

pistons

in mm 38



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in mm 25.4


9 4 + 84

1 Brake disc in mm 280Brake disc,thickness

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mm 11.5


in mm 38


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clarification Page 00-9

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Depending on the brake caliper version, there is adifferent PR no. entered on the vehicle data plate.

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Left Hand Drive (LHD) vehicles - left A-pillar, next tocentral electronics

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1LU = 15" fist caliper FN3

1LP = 15" Lucas fist caliper C54

1LE = 15" Lucas frame caliper RC 54

1LB = 16" fist caliper FN3

1LB = 16" fist caliper FNR

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The ABS brake system is divided diagonally (twocircuits). The vacuum brake servo unit boosts thebrakes pneumatically.

The hydraulic unit and control module are one unitand must always be replaced and installedtogether.

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1 - Primary piston circuit

2 - Hydraulic control unit to rear right brakecaliper

3 - Hydraulic control unit to front left brake caliper

4 - Secondary piston circuit

5 - Hydraulic control unit to rear left brake caliper

6 - Hydraulic control unit to front right brakecaliper

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With tandembrake booster

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Master brakecylinder/secondarypiston circuit tohydraulic unit


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Master brakecylinder/primarypiston circuit tohydraulic controlunit

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Hydraulic controlunit to front leftbrake caliper

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Hydraulic controlunit to rear leftbrake caliper

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Hydraulic controlunit to rear rightbrake caliper

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Hydraulic controlunit to front rightbrake caliper

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bolted to controlmodule

The hydrauliccontrol modulemust be replacedcompletely ifmalfunctioning


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Check for proper

contact

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VAG1331 torque wrench


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VAG1869/2 brake pedal depressor

Installation location:

The control module is bolted to the hydraulic unitand is located at left in the engine compartment.

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- Note radio code (for vehicles equipped withcoded anti-theft radio).

- Disconnect Ground (GND) strap from battery

- Disconnect connector from control module.

- Draw as much brake fluid as possible frombrake fluid reservoir using a bleeder bottle.

- Insert VAG1869/2 brake pedal depressor.

- Operate brake pedal using brake pedaldepressor.

- Attach bleeder hose of bleeder bottle to left-frontbrake caliper bleeder screw and open bleederscrew.

- Close front left bleeder screw.


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- Remove Ground (GND) wire from hydraulicunit.

- Place a sufficient number of lint-free clothsunder control module and hydraulic unit.

- Unscrew brake lines at hydraulic unit. Sealbrake lines and threaded holes using plugs.

- Remove hydraulic unit with control module.

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- Rest of installation is the reverse of removal.

- Bleed brake system Page 47-33 .

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Brake lines to ABS aggregate:

Thread M 10 x 1 15 Nm



17/166

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ABS allocation in Left Hand Drive (LHD) vehicles.



ABS disturbances affect the brake system and thebooster. Account for differences in brakingbehavior. When the ABS warning lamp is lit up,the rear wheels may lock prematurely duringbraking!

Hydraulic unit -a- and control module -b- are oneunit and must always be replaced together if

malfunctioning.

New control modules that are delivered as areplacement part are coded.

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A - Secondary piston circuit

B - Primary piston circuit

1 - Hydraulic control unit to rear left brakecaliper

2 - Hydraulic control unit to rear right brakecaliper


18/166


4 - Hydraulic control unit to front left brakecaliper

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with tandembrake booster

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Master brakecylinder/secondarypiston circuit to

hydraulic unit


21/166

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Master brakecylinder/primarypiston circuit tohydraulic controlunit

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The hydraulic

control modulemust be replacedcompletely ifmalfunctioning

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23/166




:$51,1*


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- For vehicles equipped with coded anti-theftradio, note radio code, obtain if necessary.


- Disengage connector from control module(arrow -1-) and disconnect (arrow -2-).






24/166



- Unscrew brake lines at hydraulic unit. Sealbrake lines and threaded holes using plugs.

- Remove hydraulic unit with control module.

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Brake lines to ABS aggregate:Thread M 10 x 1 15 Nm


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25/166

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ABS allocation in Left Hand Drive (LHD) vehicles.


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Hydraulic unit and control module are allocatedseparately in vehicle and may be removed andinstalled independently from each other.

ABS disturbances affect the brake system and thebooster. Account for differences in brakingbehavior. When the ABS warning lamp is lit up, therear wheels may lock prematurely during braking!

Hydraulic unit -a- and control module -b- are oneunit and must always be replaced together ifmalfunctioning.

New control modules that are delivered as areplacement part are coded.

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1 - Hydraulic unit

2 - ABS return flow pump

3 - Hydraulic pump for traction control withbrake pressure sensor


26/166

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A - Hydraulic unit to hydraulic pump for tractioncontrol

Identification at hydraulic unit -VLP-,

Identification at hydraulic pump for tractioncontrol -HE-

B - Hydraulic unit to secondary piston circuit of

master brake cylinder

Identification at hydraulic unit -HZ2-

1 - Hydraulic control unit to front left brakecaliper

Identification at hydraulic unit -VL-


Identification at hydraulic unit -VR-

3 - Hydraulic unit, rear right brake caliper

Identification at hydraulic unit -HR-

4 - Hydraulic unit, rear left brake caliper

Identification at hydraulic unit -HL-

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On gasolineengines vacuumis supplied fromintake manifold.

On dieselengines, avacuum pump isinstalled forvacuum creation.


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Function test

- With engineswitched off,depress brakepedal firmlyseveral times(to deplete

vacuum intool).

- Depress andhold brakepedal withaverage footpressure andstart engine. Ifbrake boosteris workingproperly, pedal

will be felt togive noticeablyunder foot(boosterassistancebecomeseffective).

If malfunctioning:replace ascomplete unitonly.

Check-valve (invacuum hose)Page 47-55

Function testPage 47-55

Removing andinstalling Page47-59

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Master brakecylinder/secondarypiston circuit tohydraulic unit

Identification at

hydraulic unit -HZ2-

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Identification athydraulic unit -VL-

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Identification athydraulic unit -VR-

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The hydrauliccontrol module

must be replacedcompletely ifmalfunctioning

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Identification athydraulic unit -

HL-

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Identification athydraulic unit -HR-

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Hydraulic unit tohydraulic pumpfor tractioncontrol

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Identification athydraulic pumpfor tractioncontrol -HE-


33/166

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For malfunctions,always replacetogether with thehydraulic pumpfor tractioncontrol

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Master brakecylinder/secondarypiston circuit tohydraulic pump fortraction control

Identification athydraulic pumpfor tractioncontrol -HZ-




34/166





:$51,1*


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35/166

- Disengage connector from control module(arrow -1-) and disconnect (arrow -2-).







- Unscrew brake lines at hydraulic unit andhydraulic pump for traction control. Seal brakelines and threaded holes using plugs.

- Remove hydraulic unit with control moduleand hydraulic pump for traction control.

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36/166


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Brake lines to ABS aggregate:



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Always replaceafterdisassembly

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Before insertingsensor, cleaninner surface ofbore hole andcoat withsecuring greaseG 000 650

Note assemblysequence: Installsensor next and

then wire;starting atsensor, install inappropriatebrackets alongwith rubbergrommets

Wire routingFig. 1

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For 16" wheels, adifferent bracketis installed Fig.

2

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With rotor forspeed sensor


38/166

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- Raise vehicle.

- Remove bolt -1- from wheel speed sensor.

- Pull ABS wheel speed sensor out of wheelbearing housing.

- Unclip wire -2- from bracket (arrow).

- Disconnect harness connector -3- for wheelspeed sensor wire.

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- Connect harness connector -3- for wheel speedsensor wire.

The two tabs at the connectors for harnessconnector -3- must align with each other.

- Clip wire -2- into bracket (arrow).

- Before inserting wheel speed sensor, clean

inner surface of bore hole and coat sensorcompletely with securing grease G 000 650

- Insert wheel speed sensor in hole of wheelbearing housing and tighten bolt Page 45-36 .

- Turn wheels completely to left and right stoppositions and check clearance to ABS wheelspeed sensor wiring.

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- Raise vehicle.

- Check rotor for dirt and damage by rotatingdrive axle.

- If rotor is damaged, drive axle must beremoved together with rotor and the outerconstant velocity joint must be replaced.

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Ejecting andpressing in

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pressing in

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41/166

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When installing,hook into controlarm first

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Before inserting

sensor, cleaninner surface ofbore hole andcoat withsecuring greaseG 000 650

Note assemblysequence: Installsensor next andthen wire;starting atsensor, install inappropriatebrackets alongwith rubbergrommets


42/166

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Only for FrontWheel Drive(FWD) vehicles

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- Raise vehicle.

- For vehicles with brake pad wear indicator,additionally rotate harness connector for brake

pad wear indicator by 90 and remove fromcable channel to side.

- Disconnect harness connector for brake padwear indicator.


43/166

- Remove bolt from wheel speed sensor.

- Remove wheel speed sensor from control arm.

- Unclip wire (arrow -A- and -B-) from bracket atcontrol arm.

- Disconnect harness connectors -1- and -2-.

- Unclip wire from bracket -3- in direction ofarrow.

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- Before inserting wheel speed sensor, cleaninner surface of bore hole and coat sensorcompletely with securing grease G 000 650

- Insert wheel speed sensor in hole of controlarm and tighten bolt Page 45-41

Rest of installation is the reverse of removal.

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- Raise vehicle.

- Check rotor for dirt and damage.


44/166

- If rotor is damaged, tension disc must be

removed and replaced.

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- Raise vehicle.

- Check rotor for dirt and damage.

- If rotor is damaged, drive axle must be

removed together with rotor and the drive axlemust be replaced along with the outerconstant velocity joint.

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A description of the construction and function ofthe ESP system is included in self study programno. 204.

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45/166

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- Disconnect battery.

- Remove passenger-side storagecompartment.

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- Pull back the front right foot carpet far enough

that the Sender for Rotation Rate -G202- andthe Sensor for transverse acceleration -G200-are accessible.

Installation location: The Sender for RotationRate -G202- and the Sensor for transverse

acceleration -G200- are secured on the wheelhousing, inside at the A-pillar.

- Disconnect connector from Sender forRotation Rate -G202- and Sensor fortransverse acceleration -G200-.

- Unscrew nuts and remove Sender forRotation Rate -G202- and Sensor fortransverse acceleration -G200-.

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- Installation is the reverse of removal.

- Code radio.

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- Disconnect battery.

- Remove passenger-side storage compartment.

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Location: ABS Control Module (w/EDL) -J104- islocated behind instrument panel on passenger-side, right next to center console.

- Fold foam matting forward.

- Disconnect connector from ABS Control Module(w/EDL) -J104-, move lever -1- in direction ofarrow to do so.

2 - Center console

- Remove control module -3-.


47/166

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- Code radio.

- Code control module.

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- Initiate basic setting

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- Put wheels in straight-ahead position.

- Remove airbag unit and steering wheel.

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- Remove trim below steering column switch.


48/166

- Remove trim above steering column switch.

- Disconnect connectors (arrows).

- Carefully lift hooks (arrows A) and removesteering angle sensor -G85-.

Arrow B points to the hole for the center positionmarking. This marking is required for installation.

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- Position the steering angle sensor -G85- untiltabs (arrows A) engage.

- A yellow dot must be visible in the hole (arrow -1-

)

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Rest of installation is the reverse of removal.

- Install airbag unit and steering wheel.


49/166

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- Code control module.

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- Initiate basic setting

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Characteristics:

Symmetrical vibration dampener -A-

VW symbol -B- behind protrusion -C-

Continuous strengthening ribs -D-

Additional technical data Page 00-1


50/166

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Characteristics:

Closed frame -A-

Brake pads visible from above


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Characteristics:

Engage retaining spring -A- in brake caliperhousing.


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Characteristics:

Engage two-part retaining spring -A- withadditional dampening sheet in brake caliperhousing.

With brake pad wear indicator -B-

16" is engraved on brake caliper -C-



51/166

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Characteristics:

Larger, outer frame -A-

With brake pad wear indicator -B-

Retaining spring is engaged in outer brakepad


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52/166

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Pads on bothsides of axle

must always bereplacedtogether.

Brake padthickness: 13.5mm

Checkingthickness

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Wear limit: 2 mmwithout brakepad mountingplate (remainingpad thickness)


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Always replace

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Servicing Page47-1

DistinguishingcharacteristicsPage 46-1


53/166

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Pads on bothsides of axlemust always be

replacedtogether.

Remove brakecaliper beforeremoving

Unventilated

brake disc:282 mm

Brake disc

thickness: 18mm

Wear limit: 15mm

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- Remove wheels.

- Unscrew lower mounting bolt for brake caliperhousing. Counterhold at guide pin.


54/166

- Swing brake caliper housing upward.

- Remove brake pads.

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- Press piston back.

- Insert brake pads.

- Swing brake caliper housing downward andtighten mounting bolts to correct tighteningtorque.

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56/166

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Bolt to brakecaliper housing

Fig. 1

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Pads on bothsides of axlemust always bereplacedtogether.

To remove, firstremove lowerbolt of brakecarrier andloosen upper bolt

Internallyventilated brake

disc: 280 mm

Brake discthickness: 24mm

Wear limit: 20mm

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57/166

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With adhesivefoil on brake padmounting plate




Brake padthickness: 13mm

Checkingthickness



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Brake padthickness: 13mm

Checkingthickness



58/166


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59/166

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Servicing Page47-5

Bolt to bridgeFig. 1

DistinguishingcharacteristicsPage 46-1

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- Position bridge using socket-head bolts andtighten.

- Insert sheet -1- (50 x 24 x 2 mm self-prepared) between surface of brake disc andunderside of bridge. This ensures sufficientclearance between bridge and brake disc.

- Press brake caliper housing/bridge againstsheet and tighten hex nuts of guide pins.

- Remove sheets and check clearance of brakedisc.


60/166

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Socket-head bolt Page 46-9

Nuts for guide pins Page 46-9


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- Remove wheels.

- Remove securing spring.

- Drive out brake pad retaining pins using drift -a-.

- Remove inner brake pad.

- Shift frame.

- Loosen outer brake pad from brake padmounting surface at bridge using a screwdriveror something similar.


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61/166

- Clean brake caliper housing, especially theadhesive surface for the brake pad, it must befree of residual adhesive and grease.

- Install inner brake pad.

- Install pad retaining pins enough that innerpad is held on.

- Remove protective foil from outer brake pad.

- Carefully insert outer brake pads.

- Press brake pad retaining pins completelythrough and install securing spring.

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63/166

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Wear limit: 20mm

Always replacepads on bothsides of axle ifworn.

Do not separatebrake discs fromwheel hub withforce or rustsolvent,otherwise brake

discs will bedamaged.

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Modified wheelbolt

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64/166

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Brake pad withretaining spring

sits at piston

Brake pad withadhesive foil onmounting platesits on outside


Checkingthickness


Pads on bothsides of axlemust always bereplaced

together.

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Insert in bothholes of brakecaliper housing


65/166

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Supplied as pre-assembledreplacement partwith sufficientgrease on guidepins

Use repair kitwhen protectivecaps aredamaged.

Use greasepacket suppliedto lubricate guidepins

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66/166

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- Remove wheels.


67/166

- Remove protective caps (arrows).

- Disengage brake pad retaining spring frombrake caliper housing and remove.

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- Remove both guide pins from brake caliper.

- Remove brake caliper housing and set asideso that the weight of the brake caliper doesnot burden or damage the brake hose.

- Remove brake pads from brake caliperhousing or from brake carrier.


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68/166

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- Insert brake pad with retaining spring in brakecaliper housing.

- Install outer brake pad on brake carrier.

- Tighten brake caliper housing to brake carrierusing both guide pins (25 Nm).

- Install both protective caps.

- Place one bow of the retaining spring under thebrake carrier and insert a tab into hole in housing(arrow A).Tension second bow under the brake

carrier and engage second tab in hole (arrow B).

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69/166

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Always replaceafter

disassembly



70/166

6RFNHWKHDGEROW1P

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Brake disc

thickness: 26mm

Wear limit: 22mm


Do not separate

brake discs fromwheel hub withforce or rustsolvent,otherwise brakediscs will bedamaged.

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With wearindicator

- When theappropriatewear limit hasbeen reached(limit: 2 to 3

mm), thewarning lamplights up


Checkingthickness


71/166


Wear limit: 8 mm(including brake padmounting plate)

Removing andinstalling Page 46-30

Brake pad withretaining spring sits at

piston

Brake pad withadhesive foil onbacking plate sits onoutside

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For padreplacement,

remove frombracket, -item no.12 -

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with additionaldampening sheet

Insert in bothholes of brakecaliper housing

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Use repair kitwhen protective


72/166

caps aredamaged.


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73/166

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Before insertingsensor, cleaninner surface ofbore hole andcoat with

securing greaseG 000 650

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- Remove wheels.


74/166

- Remove protective caps (arrows).

- Disengage brake pad retaining spring frombrake caliper housing and remove.

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- Disconnect harness connector -1- for brakepad wear indicator.

- Lift securing strap slightly at bottom of

connector -2- and then rotate 90 .

- Remove bottom of connector from bracketand unclip wire from protective cap -3- forvent valve.


75/166

- Remove both guide pins from brake caliper.




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- Place outer brake pad with wear indicator onbrake carrier.

- Tighten brake caliper housing to brake carrierusing both guide pins (25 Nm).

- Insert lower part of connector for brake padwear indicator into bracket at brake caliper.



76/166

- Place one bow of the retaining spring underthe brake carrier and insert a tab into hole inhousing (arrow A).Tension second bow underthe brake carrier and engage second tab inhole (arrow B).

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77/166


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78/166

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79/166

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Wear limit: 22mm

Internallyventilated brake

disc: 313 mm


Do not separatebrake discs from

wheel hub withforce or rustsolvent,otherwise brakediscs will bedamaged.

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80/166

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For padreplacement,remove frombracket, -item no.22 -

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Thickness 14mm

Brake pad withretaining springsits at piston

- When theappropriate

wear limit hasbeen reached(limit: 2 to 3mm), thewarning lamplights up

Brake pad withadhesive foil onbacking plate sitson outside

Wear limit: 7 mmincluding backingplate

Checkingthickness

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81/166

46-41

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Use repair kit

when protectivecaps aredamaged.



82/166

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Do not unscrewbrake hose whenreplacing brakepad

Removing:

- Remove brakepads -item no.13 - Page46-41

- InsertVAG1869/2brake pedaldepressor

- Unscrew brake

hose -item no.23 - from brakecaliper

Installing:

- Install brakepads -item no.13 - Page46-42

- Attach brake

hose -item no.23 - at brakecaliper

- RemoveVAG1869/2brake pedaldepressor

- Bleed brakesystem Page47-33

Servicing Page47-19

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83/166

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- Remove protective caps.


84/166

- Using screwdriver, pry off brake pad retainingspring from brake caliper housing (arrow) andremove.

- Disconnect harness connector of brake padwear indicator.

- Lift securing strap slightly at bottom of

connector -1- and then rotate 90 .

- Remove bottom of connector from bracket indirection of arrow.

- Remove both guide pins (arrows) from brakecaliper.



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,QVWDOOLQJ

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3UHVVSLVWRQEDFNLQWRFDOLSHUKRXVLQJXVLQJUHVHWWLQJWRROEHIRUHLQVHUWLQJQHZEUDNHSDGV%HIRUHSXVKLQJEDFNWKHSLVWRQVLSKRQVRPHRIWKHEUDNHIOXLGRXWRIWKHEUDNHIOXLGUHVHUYRLU2WKHUZLVHHVSHFLDOO\LIUHVHUYRLUKDVEHHQ


85/166

WRSSHGRIIIOXLGZLOORYHUIORZDQGFDXVHGDPDJH



- Install outer brake pad on brake carrier.

- Tighten brake caliper housing to brake carrierusing both guide pins Page 46-34 .


- Install retaining spring in brake caliperhousing.

1RWH

$IWHUUHSODFLQJEUDNHSDGVDQGEHIRUHPRYLQJYHKLFOHDOZD\VGHSUHVVEUDNHSHGDOVHYHUDOWLPHVILUPO\WRSURSHUO\VHDWEUDNHSDGVLQWKHLUQRUPDORSHUDWLQJSRVLWLRQ

&KHFNEUDNHIOXLGOHYHODIWHUUHSODFLQJEUDNHSDG


86/166

5HDUEUDNHVVHUYLFLQJZKHHOV+H[EROW



:DVKHU

6RFNHWKHDGEROW1P

%UDNHGLVF

Thickness 12mm

Wear limit: 10mm


+H[EROW1P


87/166

%DFNLQJSODWH

+H[EROW

6SULQJIRUEUDNHSUHVVXUHUHJXODWRU

Adjusting brakepressureregulator Page47-41

Not installed invehicles with AllWheel Drive(AWD), ABSBosch 5.3 andclosedconstruction

(box-type van,combi, caravelle,multivan)

+H[QXWWLJKWHQWR1P

5HWDLQLQJSODWH

Mark installationposition beforeremoving

%UDFNHW

&RQWURODUP

Removing andinstalling

5HSDLU0DQXDO6XVSHQVLRQ:KHHOV6WHHULQJIURPP\5HSDLU*URXS5HDU

VXVSHQVLRQVHUYLFLQJ


88/166

6HOIORFNLQJKH[QXW

Always replace



7HQVLRQGLVF

With rotor for

speed sensor

$%6ZKHHOVSHHGVHQVRU

6RFNHWKHDGVFUHZ1P

+H[EROW1P

:KHHOEHDULQJ

6QDSULQJ

Check for properfitting

:KHHOKXE


89/166

%UDNHFDUULHUZLWKJXLGHSLQVDQGSURWHFWLYHFDS

Vehicles up toVIN no.70ZWH130 482or 70ZWX121

939 withoutbrake padretention plates


If protective caps

or guide pins aredamaged, installrepair kit. Usegrease packetsupplied tolubricate guidepins

%UDNHSDGV

Thickness: 11.5without mounting

plate

Checkingthickness:


Wear limit: 2 mmwithout brakepad mounting

plate (remainingpad thickness)


Removing andinstalling Page


90/166

46-50

+H[EROWVHOIORFNLQJ1P

Always replace

When looseningand tightening,counter-hold onguide pin

*XLGHSLQV

3URWHFWLYHFDS

%UDNHFDOLSHU

Modification:Adapted forvehicles fromVIN no.70ZWH130 483and 70ZWX121940 withimplementation

of the brake padretention plate -item no. 29 - andbrake carrier -item no. 30 -.

Servicing Page47-25

3DUNLQJEUDNHFDEOH

Parking brake,adjusting Page46-55

6SULQJFODPS


91/166

%UDNHSDGUHWHQWLRQSODWH

Installed invehicles fromVIN no.70ZWH130 483and 70ZWX121

940

Only install withnew brake carrier-item no. 30 -

Always replacewhen pads arereplaced

%UDNHFDUULHUZLWKJXLGHSLQVDQG

SURWHFWLYHFDS

Installed invehicles fromVIN no.70ZWH130 483and 70ZWX121940 withimplementationof the brake padretention plate -item no. 29 -.


If protective capsor guide pins aredamaged, installrepair kit. Use

grease packetsupplied tolubricate guidepins


92/166


5HPRYLQJ

1RWH

:KHQUHPRYLQJPDUNEUDNHSDGVWKDWZLOOEHXVHGDJDLQ,QVWDOOLQWKHVDPHSRVLWLRQRWKHUZLVH

EUDNLQJHIIHFWZLOOEHXQHYHQ

- Remove wheels.

- Remove parking brake cable at brake caliper.

- Unscrew attachment bolts (arrows) from brakecaliper housing.

- Remove brake caliper housing and set aside sothat the weight of the brake caliper does not

burden or damage the brake hose.


93/166


- If present, remove brake pad retention plates.

,QVWDOOLQJ

1RWH

%HIRUHSXVKLQJEDFNWKHSLVWRQVLSKRQVRPHRIWKHEUDNHIOXLGRXWRIWKHEUDNHIOXLGUHVHUYRLU:KHQVLSKRQLQJEUDNHIOXLGDOZD\VXVHDSODVWLFEOHHGHUERWWOHWKDWLVXVHGH[FOXVLYHO\IRUEUDNHIOXLG%UDNHIOXLGLVSRLVRQRXV1(9(5VLSKRQEUDNHIOXLGZLWK\RXUPRXWK

- Brake caliper housing hangs on a hook (arrowB).

- Install pistons at knurled wheel of special tool-3272- by turning toward right. Do not damageprotective caps.

1RWHV

,QVHUWVSHFLDOWRROVRWKDWWKHFROODUDUURZRIWKHWRROUHVWVDWEUDNHFDOLSHU

)RUSLVWRQVWKDWDUHGLIILFXOWWRPRYHDQRSHQHQGZUHQFKVL]HPPFDQEH

DSSOLHGDWWKHDSSURSULDWHZUHQFKVXUIDFHDUURZ$

:KHQSLVWRQLVPLVDGMXVWHGZLWKDSLVWRQUHVHWWLQJWRRORULIIRRWEUDNHLVRSHUDWHGWKHDXWRPDWLFUHVHWIXQFWLRQRIWKHEUDNHFDOLSHULVFRPSURPLVHG

)RUYHKLFOHVXSWR9,1QR=:+DQG=:;

- Thoroughly clean contact surfaces for brakepads at brake carrier, remove corrosion.

- Insert brake pads in brake carrier.


94/166

- Using a feeler gauge -A-, measure play betweenbrake pads -1- and contact surfaces for brakepads -2- at brake carrier.

Play: At least 0.4 mm to ensure proper functionof brake system.

If play is less than 0.4 mm, clean contact

surfaces for brake pads at brake carrier again.


- Lightly grease contact surfaces for brake padsusing solid lubricant G000 650.

- Insert brake pads in brake carrier.

)RUYHKLFOHVIURP9,1QR=:+DQG=:;

- Thoroughly clean contact surfaces for brake padretention plates at brake carrier, removecorrosion.

- Insert brake pad retention plates and brake

pads in brake carrier.

- Using a feeler gauge -A-, measure play betweenbrake pads -1- and brake pad retention plates -2- at brake carrier.


If play is less than 0.4 mm, clean contactsurfaces for brake pad retention plates at brake

carrier again.

&RQWLQXDWLRQIRUDOOYHKLFOHV


95/166

- Secure brake caliper housing using new self-

locking bolts.

5HSDLUNLWLQFOXGHVIRXUVHOIORFNLQJKH[EROWVZKLFKPXVWDOZD\VEHLQVWDOOHG

- Secure parking brake cable (arrow) at brakecaliper housing.

- Adjusting parking brake Page 46-55 .

'RQRWRSHUDWHIRRWEUDNHXQWLODIWHUSDUNLQJEUDNHLVDGMXVWHG

- Mount wheels.

1RWHV



3DUNLQJEUDNHDGMXVWLQJ

1RWH

2QO\UHDGMXVWDIWHUUHSODFLQJSDUNLQJEUDNHFDEOHVEUDNHFDOLSHUVDQGEUDNHGLVFV

-Parking brake lever in released position. Tightenadjustment nut (arrow) in until...


96/166

- ... the levers (arrow) lift off stops at brakecalipers.

- Maximum permitted play is 1.0 mm to stop.

- Tighten parking brake and then release again.

1RWH

%HFDXVHWKHUHDUEUDNHVKDYHDQDXWRPDWLFDGMXVWPHQWIXQFWLRQUHDGMXVWLQJWKHSDUNLQJEUDNHLVXVXDOO\QRWQHFHVVDU\IROORZLQJLQLWLDODGMXVWPHQW

- Check whether wheels turn freely.

5HDUEUDNHVVHUYLFLQJZKHHOV6RFNHWKHDG

VFUHZ1P

+H[EROW1P

$%6ZKHHOVSHHGVHQVRU


+DUQHVVFRQQHFWRU

For padreplacement,remove frombracket, -item no.7 -

&RQWURODUP


97/166

+H[EROWVHOIORFNLQJ1P

Always replace

When looseningand tightening,counter-hold on

guide pin

%UDFNHW

*XLGHSLQV

3URWHFWLYHFDS

%UDNHSDGV


With wearindicator

- Warning lamplights up whenrelevant wearlimit has beenreached

Thickness: 13.5mm

Wear limit: 8.5mm including

backing plate

Checkingthickness:

5HSDLU0DQXDO0DLQWHQDQFH:RUNSURFHGXUHGHVFULSWLRQ)URQWDQGUHDUEUDNH


98/166


%UDNHSDGUHWHQWLRQSODWH

Always replacewhen pads arereplaced

5HWDLQLQJVSULQJ

Clip into brakecaliper

Secures wire forbrake pad wearindicator

%UDNHFDOLSHU

Do not unscrewbrake hose when

replacing brakepad

Removing:

- Remove brakepads -item no.10 - Page46-61

- InsertVAG1869/2

brake pedaldepressor

- Unscrew brakehose withbrake caliper

Installing:

- Install brakepads -item no.


99/166

10 - Page46-63

- Attach brakehose withbrake caliper

- Remove

VAG1869/2brake pedaldepressor

- Bleed brakesystem Page47-33

After servicing orreplacing, parkingbrake cable must beadjusted first.

Parking brake,adjusting Page 46-55

Servicing Page 47-

25

6SULQJFODPS

3DUNLQJEUDNHFDEOH

%UDNHFDUULHUZLWKJXLGHSLQVDQGSURWHFWLYHFDS

Supplied as pre-

assembledreplacement partwith sufficientgrease on guidepins

If protective capsor guide pins aredamaged, installrepair kit. Usegrease packet


100/166

supplied tolubricate guidepins

6RFNHWKHDGEROW1P

%UDNHGLVF

Thickness: 13.5mm

Wear limit: 11.5mm


+H[EROW1P

%DFNLQJSODWH

Allocation

3DUWVFDWDORJ

%DFNLQJSODWH

To remove, drillout pop rivet -item no. 22 -

Allocation

3DUWVFDWDORJ

3RSULYHW

4x

&RQQHFWLQJEUDFH


101/166



3272 reset tool


1RWH


5HPRYLQJ

- Remove wheels.

- Unclip spring clamp -1-.


102/166

- Remove parking brake cable -2- from brakecaliper.

- Rotate harness connector for brake pad wear

indicator by 90 and remove from cablechannel toward side.

- Disconnect harness connector for brake pad

wear indicator.

- Unclip retaining spring -A- for brake pad wearindicator wire from brake caliper.

- Unscrew attachment bolts (arrows) from brakecaliper housing.

- Remove brake caliper housing and set aside sothat the weight of the brake caliper does notburden or damage the brake hose.

- Remove brake pads and brake pad retentionplates (arrows).

,QVWDOOLQJ

1RWH

%HIRUHSXVKLQJEDFNWKHSLVWRQVLSKRQVRPHRIWKHEUDNHIOXLGRXWRIWKHEUDNHIOXLGUHVHUYRLU:KHQVLSKRQLQJEUDNHIOXLGDOZD\VXVHDSODVWLFEOHHGHUERWWOHWKDWLVXVHGH[FOXVLYHO\IRUEUDNH

IOXLG%UDNHIOXLGLVSRLVRQRXV1(9(5VLSKRQEUDNHIOXLGZLWK\RXUPRXWK

- Brake caliper housing hangs on a hook (arrowB).


103/166

- Install pistons at knurled wheel of special tool

-3272- by turning toward right. Do not damageprotective caps.

,QVHUWVSHFLDOWRROVRWKDWWKHFROODUDUURZRIWKHWRROUHVWVDWEUDNHFDOLSHU

)RUSLVWRQVWKDWDUHGLIILFXOWWRPRYHDQ

RSHQHQGZUHQFKVL]HPPFDQEHDSSOLHGDWWKHDSSURSULDWHZUHQFKVXUIDFHDUURZ$

:KHQSLVWRQLVPLVDGMXVWHGZLWKDSLVWRQUHVHWWLQJWRRORULIIRRWEUDNHLVRSHUDWHGWKHDXWRPDWLFUHVHWIXQFWLRQRIWKHEUDNHFDOLSHULVFRPSURPLVHG

- Thoroughly clean contact surfaces for brake padretention plates at brake carrier, removecorrosion.

- Insert brake pad retention plates and brake padsin brake carrier.

- Using a feeler gauge -A-, measure play betweenbrake pads -1- and brake pad retention plates -2- at brake carrier.


If play is less than 0.4 mm, clean contactsurfaces for brake pad retention plates at brakecarrier again.


104/166

- Insert pad retaining springs (arrows) and brakepads, inner brake pad with wire for brake padwear indicator, in the brake carrier.

- Secure brake caliper housing using new self-locking bolts.

1RWH

5HSDLUNLWLQFOXGHVIRXUVHOIORFNLQJKH[EROWVZKLFKPXVWDOZD\VEHLQVWDOOHG

- Press brake lever -3- in direction of arrow andengage parking brake cable -2-.

- Install spring clamp -1-.

- Connect connection -5- for brake pad wearindicator and press it into the cable channel -4-.

- Rotate harness connector in cable channel by

90 .


'RQRWRSHUDWHIRRWEUDNHXQWLODIWHUSDUNLQJEUDNHLVDGMXVWHG

- Mount wheels.

1RWHV




105/166

3DUNLQJEUDNHFDEOHUHPRYLQJDQGLQVWDOOLQJ

)URQWSDUNLQJEUDNHFDEOHUHPRYLQJDQGLQVWDOOLQJ

5HPRYLQJ

- Release parking brake.

- Raise vehicle.

- Remove nut (arrow) from front parking brake

cable.

- Pry both brackets out from underbody.

- Remove trim from parking brake lever.

- Place brake lever in upper end position.

- Remove cable tie from locking latch.

- Disengage front parking brake lever fromlocking latch -1- (arrow).

,QVWDOOLQJ


106/166

- Guide front parking brake cable through

underbody into interior.

- Place brake lever in upper end position.

- Engage front parking brake cable in locking

latch -1- (arrow).

- Attach new cable ties at locking latch in front offront parking brake.

- Attach trim at parking brake lever.

- Raise vehicle.

- Clip brackets into underbody.

- Install nut (arrow) at front parking brake cable.


3XOOOHYHUUHPRYLQJDQGLQVWDOOLQJ

5HPRYLQJ

- Release parking brake.

- Raise vehicle.


107/166

- Remove nut (arrow) from front parking brakecable.

- Disengage pull-lever from compensatorbracket.

- Remove pull-lever -1- from rear parking brakecable.

,QVWDOOLQJ

- Engage pull-lever -1- in rear parking brakecable -2-.

- Engage pull-lever in compensator bracket.


108/166

- Install nut (arrow) at front parking brake cable.


5HDUSDUNLQJEUDNHFDEOHUHPRYLQJDQG

LQVWDOOLQJ

5HPRYLQJ

- Unclip spring clamp -1-.

- Remove parking brake cable -2- from brakecaliper.

- Disengage parking brake cable from bracket atcontrol arm (arrow A).


109/166

- Unclip parking brake cable from bracket atunderbody (arrow).

- Disengage parking brake cable -1- from pull-

lever -2-.

,QVWDOOLQJ

- Engage parking brake cable -1- in pull-lever -2-.

- Clip parking brake cable into bracket at

underbody.

- Engage parking brake cable in bracket atcontrol arm (arrow A).


110/166

- Attach parking brake cable -2- at brake

caliper.

- Clip in spring clamp -1-.


3DUNLQJEUDNHOHYHUUHPRYLQJ

DQGLQVWDOOLQJ+DQGOH

Remove forward,first pressretaining tabsunder handledownward

7ULPIRUSDUNLQJ

EUDNHOHYHU

7ULP

%XWWRQ

&RPSUHVVLRQVSULQJ

Installationposition Fig.1

6SULQJVOHHYH

Installationposition Fig.1

/DWFKURG

/RFNLQJODWFK


111/166

/RFNLQJZDVKHU

3DUNLQJEUDNHOHYHU

3LQ

6HOIORFNLQJQXW1P

Not installed onRight Hand Drive(RHD) vehicles

Always replace

3DUNLQJEUDNH

FDUULHU

Welded tostructure onRight Hand Drive(RHD) vehicles

&RQWDFWVZLWFK

([SDQGLQJULYHW

6HOIORFNLQJQXW

1P

Always replace

7RRWKHGVHJPHQW

Only for RightHand Drive(RHD) vehicles

3XOOOHYHU


112/166

%UDFNHW

5HWXUQVSULQJ

6SULQJEUDFNHW

$GMXVWPHQWQXW

Parking brake,adjusting Page46-55

3XOOFDEOH

Only installed inplatform trucks

3DUNLQJEUDNHFDEOH

)LJ ,QVWDOODWLRQSRVLWLRQRIVSULQJVOHHYH

1 - Locking latch

2 - Spring sleeve

3 - Compression spring

Dimension -a- approx. 126 mm

Slide spring sleeve -2- onto coil spring -3-when installing.

4 - Button

Screw in until stop.


113/166

5 - Latch rod

6 - Parking brake lever

%UDNHSHGDODVVHPEO\RYHUYLHZ:$51,1*

7KHSDWKRIWKHEUDNHSHGDOPXVWQRWEHVKRUWHQHGYLDH[WUD

IORRUPDWV

1RWH

/XEULFDWHDOOEHDULQJORFDWLRQVZLWK*OXEULFDQWEHIRUHLQVWDOOLQJ

&DS

%UDNHIOXLGUHVHUYRLU

With sieve

Switch for brakefluid levelindicatorintegrated inreservoir

6HDOLQJSOXJV

Coat with brake

fluid and pressinto expansiontank


114/166

+H[QXWWLJKWHQWR1P


Cannot beserviced.

Replace ascomplete unit ifmalfunctioning.

Bleeding Page47-35

6HDO

Always replace

/RFNLQJZDVKHU

Check for securefitting

3LQ

Lubricate with G000 602

6HOIORFNLQJQXW1P

Always replace

3UHVVXUHURGZLWKIRUNKHDGHGEUDNHERRVWHU


115/166

7DQGHPEUDNHERRVWHU

On gasolineengines vacuumis supplied fromintake manifold.

On dieselengines, avacuum pump isinstalled forvacuum creation.

Function test

- With engineswitched off,depress brakepedal firmly

several times(to depletevacuum intool).

- Depress andhold brakepedal withaverage footpressure andstart engine. Ifbrake booster

is workingproperly, pedalwill be felt togive noticeablyunder foot(boosterassistancebecomeseffective).

If malfunctioning:replace as

complete unitonly.

Check-valve (invacuum hose)Page 47-55

Function testPage 47-55

Removing and


116/166

installing Page47-59

*DVNHW

For tandembrake booster

/RFNLQJZDVKHU

5HWXUQVSULQJIRUEUDNHSHGDO

%XVKLQJIRUEUDNH

SHGDO

%UDNHSHGDO

3LYRWSLQIRUEUDNHSHGDO

%UDNHOLJKWVZLWFK

Secure brakepedal at pressurerod of brake

booster beforeinstalling brakelight switch

Before installing,remove plungercompletely

Guide switchthroughassembly holeand install by

rotating 90toward right.


117/166

+H[EROW1P

0RXQWLQJEUDFNHW

+H[EROW1P

0RXQWLQJSODWH

&URVVSDQHO

%UDNHSHGDOUHPRYLQJDQGLQVWDOOLQJ

1RWHV

/XEULFDWHDOOEHDULQJDQGFRQWDFWVXUIDFHVZLWK0R6

OXEULFDQW

5HPRYHRQO\WKHIRUNKHDGFRQQHFWLRQWREUDNHSHGDOZKHQUHPRYLQJWKHEUDNHERRVWHU

5HPRYLQJ

- Remove covers before removing brake pedal.


118/166

- Remove brake light switch.

- Remove securing disc at pins for fork-headconnection to brake pedal.

- Remove pins.

- Remove securing disc of pivot pins for clutchand brake pedal.

- Remove clutch pedal.

5HSDLU0DQXDO0DQXDO7UDQVPLVVLRQ5HSDLU*URXS&OXWFKPHFKDQLVPVHUYLFLQJ

5HPRYLQJDQGLQVWDOOLQJFOXWFKSHGDO

- Remove pivot pins.

- Remove brake pedal.

,QVWDOOLQJ


- Adjust brake light switch Page 46-80 , itemno. 18 .


119/166

)URQWEUDNHFDOLSHUVHUYLFLQJ)URQWEUDNHFDOLSHUVHUYLFLQJ/XFDV

&ILVWFDOLSHUZKHHOV

1RWHV

,QVWDOOFRPSOHWHUHSDLUNLWZKHQVHUYLFLQJ

$SSO\DWKLQFRDWRIEUDNHF\OLQGHUSDVWH*$WREUDNHF\OLQGHUVSLVWRQVDQGVHDOV

%UDNHFDOLSHUKRXVLQJ

6HDO


3URWHFWLYHFDS

Do not damagewhen installingpiston

3LVWRQV


)URQWEUDNHFDOLSHUSLVWRQVUHPRYLQJDQGLQVWDOOLQJ/XFDV&ILVWFDOLSHUZKHHOV



120/166

3409 wedge

Brake piston resetting tool

5HPRYLQJ

- Force piston from brake caliper housing usingcompressed air.

1RWH

3ODFHDZRRGHQERDUGLQWRWKHUHFHVVRIWKH

FDOLSHUKRXVLQJWRFDWFKWKHSLVWRQVRLWLVQRWGDPDJHG

- Removing seal using 3409 assembly wedge.

1RWH

:KHQUHPRYLQJPDNHVXUHWKDWVXUIDFHRIF\OLQGHULVQRWGDPDJHG

,QVWDOOLQJ

- Use only appropriate solvent to clean surfaces

of piston and protective seal, then dry.

- Apply thin coat of brake cylinder paste G 052150 A2 to piston and protective seal beforeinstalling.

- Install sealing ring in brake caliper housing.


121/166

- Place protective cap with outer sealing lip on

piston.

- Using 3409 assembly wedge, insert innersealing lip into cylinder groove.

1RWH

+ROGSLVWRQLQIURQWRIFDOLSHUKRXVLQJIRUWKLVSURFHGXUH

- Press piston into brake caliper housing usingpiston resetting tool.

1RWH

2XWHUVHDOLQJOLSRISURWHFWLYHFDSZLOOWKHQHQJDJHLQSLVWRQJURRYH


122/166

)URQWEUDNHFDOLSHUVHUYLFLQJ/XFDV5&IUDPHFDOLSHUZKHHOV

1RWHV

,QVWDOOFRPSOHWHUHSDLUNLWZKHQVHUYLFLQJ

%UDNHFDOLSHUGLVDVVHPEOLQJDQGDVVHPEOLQJ 3DJH

$SSO\DWKLQFRDWRIEUDNHF\OLQGHUSDVWH*$WR

EUDNHF\OLQGHUVSLVWRQVDQGVHDOV

9HQWVFUHZ

%UDNHFDOLSHUKRXVLQJ

6HDO


3URWHFWLYHFDS


3LVWRQV


)URQWEUDNHFDOLSHUSLVWRQVUHPRYLQJDQGLQVWDOOLQJ/XFDV5&IUDPHFDOLSHUZKHHOV


123/166


3409 wedge


5HPRYLQJ


1RWH

3ODFHDZRRGHQERDUGLQWRWKHUHFHVVRIWKHFDOLSHUKRXVLQJWRFDWFKWKHSLVWRQVRLWLVQRWGDPDJHG


1RWH


,QVWDOOLQJ

- Use only appropriate solvent to clean surfacesof piston and protective seal, then dry.




124/166


piston.

- Insert inner sealing lip into cylinder groove.

1RWH



1RWH



125/166

)URQWEUDNHFDOLSHUVHUYLFLQJ)1ILVWFDOLSHUZKHHOV

1RWHV

,QVWDOOFRPSOHWH

UHSDLUNLWZKHQVHUYLFLQJ


'XVWFDS

Push onto

bleeder valve

%OHHGHUYDOYH

Apply thin coat ofbrake cylinderpaste G 052 150A2 to threadsbefore screwingin

&DSV

Insert inmountingbushing

*XLGHSLQV1PIWOE

%HDULQJEXVKLQJ

Insert in brakecaliper housing


126/166

%UDNHFDOLSHUKRXVLQJ

%UDNHFDUULHU


5HWDLQLQJVSULQJ

Insert with bothends in holes ofbrake caliperhousing

6HDO


3LVWRQV


3URWHFWLYHFDS


)URQWEUDNHFDOLSHUSLVWRQVUHPRYLQJDQGLQVWDOOLQJ)1ILVWFDOLSHUZKHHOV



127/166

3409 wedge


5HPRYLQJ


1RWH




1RWH


,QVWDOOLQJ






128/166


piston.


1RWH



1RWH



129/166


1RWHV

,QVWDOOFRPSOHWH



'XVWFDS

Push onto

bleeder valve


%OHHGHUYDOYH

Apply thin coat ofbrake cylinderpaste G 052 150A2 to threadsbefore screwingin

&DSV


*XLGHSLQV1PIWOE


130/166

%HDULQJEXVKLQJ


%UDNHFDOLSHUKRXVLQJ

%UDNHFDUULHU


5HWDLQLQJVSULQJ

Insert with bothends in holes ofbrake caliperhousing

6HDO


3LVWRQV


3URWHFWLYHFDS


)URQWEUDNHFDOLSHUSLVWRQVUHPRYLQJDQGLQVWDOOLQJ)1ILVWFDOLSHUZKHHOV



131/166

3409 wedge


5HPRYLQJ


1RWH




1RWH


,QVWDOOLQJ






132/166


piston.


1RWH



1RWH



133/166


1RWHV

,QVWDOOFRPSOHWH


1HZEUDNHFDOLSHUVDUHILOOHGZLWKEUDNHIOXLGDQGDUHSUHEOHG


'XVWFDS

Push ontobleeder valve


%OHHGHUYDOYH

Apply thin coat of

brake cylinderpaste G 052 150A2 to threadsbefore screwingin

&DSV



134/166

*XLGHSLQV1PIWOE

%HDULQJEXVKLQJ


2x

%UDNHFDOLSHUKRXVLQJ

%UDNHFDUULHU


5HWDLQLQJVSULQJ

Insert both endsbetween exteriorof brake caliperhousin

Servicio Sistemas de Frenos

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Transcript of Servicio Sistemas de Frenos