Volkswagen Golf / Golf GTI / Golf Variant. Manual — part 800
– Turn the spindle all the way in the flange unit.
– Turn the spindle back.
– Loosen the hex socket head bolts diagonally.
– Remove the brake line from the flanging tool, clean the brake
line and the flared head and check.
Briefly rinse part of brake line remaining in vehicle:
– Connect the Brake Charger/Bleeder Unit - VAS5234- , place
the bleeder container hose on the flared head of the brake line
and run the Brake Charger/Bleeder Unit - VAS5234- briefly
until some brake fluid runs through.
– Clean the brake line with compressed air.
– Join brake lines with connecting piece -E-.
– Assemble brake line.
– Bleed the brake system. Refer to
6
Hydraulic System
⇒ “6.1 Brake Fluid General Information”, page 132
⇒ “6.2 Hydraulic System, Standard Bleeding”, page 132
⇒ “6.3 Hydraulic System, Post-Bleeding”, page 133
⇒ “6.4 Checking for Leaks”, page 133
6.1
Brake Fluid General Information
WARNING
Only use new brake fluid conforming to VW standard (VW 501
14).
Note
♦
Brake fluid is poisonous. Due to its caustic nature, it must also
never come in contact with paint.
♦
Brake fluid is hygroscopic, meaning that it absorbs moisture
from the surrounding air, and must therefore be stored in air-
tight containers.
♦
Rinse any spilled brake fluid with plenty of water.
Brake Fluid, Changing
Refer to ⇒ Maintenance ; Booklet 36.1 ; Procedure Descriptions;
Brake and Clutch System, Changing Brake Fluid .
6.2
Hydraulic System, Standard Bleeding
Special tools and workshop equipment required
♦ Brake Charger/Bleeder Unit - VAS5234-
♦ Brake Bleeding Tool Set - VAS6564-
Note
♦
The bleeding of hydraulic system using the Brake Charger/
Bleeder Unit - VAS5234- is described.
♦
A positive pressure of 2 bar (29 psi) required to bleed the ABS
Hydraulic Unit - N55- .
– Remove the rear wheels on vehicles with 15" rims.
Adhere strictly to work sequence when bleeding brake system.
– Connect the Brake Charger/Bleeder Unit - VAS5234-
– Open the bleeder valves in the specified sequence and bleed
the brake calipers.
1- Front left brake caliper
2 - Right front brake caliper
3 - Left rear brake caliper
4 - Right rear brake caliper
Use suitable bleeder hose. It must fit tightly on bleeder valve so
that no air gets into brake system.
– Vehicles with bleeder bottle hose attached, leave bleeder
valve open long enough that brake fluid exits without bubbles.
6.3
Hydraulic System, Post-Bleeding
Perform a post-bleeding when:
♦ The brake pedal travel is too long, or the so-called soft brake
pedal
A second technician is required during the post-bleeding.
– Connect the Brake Charger/Bleeder Unit - VAS5234-
– Press brake pedal forcefully and hold.
– Open bleeder valve at brake caliper.
– Press brake pedal down onto stop.
– Close bleeder valve with pedal depressed.
– Release brake pedal slowly.
Note
This bleeding procedure must be performed five times per brake
caliper.
Bleeding sequence:
1- Front left brake caliper
2 - Right front brake caliper
3 - Left rear brake caliper
4 - Right rear brake caliper
Note
A road test must be performed after bleeding. During this, at least
one ABS regulation must be performed!
6.4
Checking for Leaks
Special tools and workshop equipment required
♦ Brake Pressure Gauge - VAG1310A-
♦ Brake Pressure Gauge - Adapter M10 - VAG1310/6-
Test Prerequisites
• Brake system ( ABS Hydraulic Unit - N55- , brake hoses, brake
lines and brake calipers) operating properly and free of leaks.
Checking
– Remove the bleeder valve at one front brake caliper.
– Attach and bleed the Brake Pressure Gauge - VAG1310A- .
– Apply pressure to brake pedal until the gauge indicates a
pressure of 50 bar (725 psi). The pressure must not drop by
more than 4 bar (58 psi) during the test period of 45 seconds.
Replace master cylinder if pressure drops greatly.
7
Special Tools
Special tools and workshop equipment required
♦ Brake Caliper Tool - T10165-
♦ Sealing Tool - T10249-
♦ Brake Pressure Gauge - VAG1310A-
♦ Brake Pressure Gauge - Adapter M10 - VAG1310/6-
♦ Torque Wrench 1331 5-50Nm - VAG1331-
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