Skoda Octavia Mk1 01 Running Gear

SKODA OCTAVIA
MK1
RUNNING GEAR
CHASSIS
RUNNING GEAR..........................................................................................................................................10
CHASSIS.........................................................................................................................................................10
TECHNICAL DATA......................................................................................................................................10
CHASSIS - SPECIFIED VALUES........................................................................................................................10
STEERING......................................................................................................................................................13
BRAKES.........................................................................................................................................................14
Brake variants and their assignment........................................................................................................14
Brake fluid................................................................................................................................................17
WHEELS, TYRES............................................................................................................................................18
FRONT SUSPENSION, DRIVE SHAFTS..................................................................................................21
REPAIRING FRONT WHEEL SUSPENSION.........................................................................................................21
l - Summary of components assembly carrier, anti-roll bar, track cotrol arm.........................................22
Removing and installing the track control arm........................................................................................25
Pressing out and in the bearing for the track control arm.......................................................................28
Removing and installing assembly carrier...............................................................................................31
Pressing out and in rubber-metal bearing................................................................................................34
II - Summary of components of the wheel bearing, suspension strut, drive shaft, brake.........................35
Repairing wheel bearing housing.............................................................................................................40
Inspecting the steering joint.....................................................................................................................43
Removing and installing the steering joint...............................................................................................44
Remove and install suspension strut and wheel bearing housing............................................................45
Repairing the suspension strut.................................................................................................................49
Inspecting the shock absorber..................................................................................................................52
Disposing of the shock absorber..............................................................................................................54
Removing and installing a drive shaft......................................................................................................57
REPAIRING DRIVE SHAFT...............................................................................................................................61
Repairing drive shaft with outer and inner CV joint VL 3700.................................................................64
Inspecting outer CV joint..........................................................................................................................73
Inspecting inner CV joint..........................................................................................................................75
Repairing drive shaft with inner tripod joint AAR 2900 and outer CV joint............................................79
Disassembling and assembling the tripod joint AAR 2900......................................................................82
Repairing drive shaft with inner tripod joint AAR 2000 and outer CV joint............................................87
Disassembling and assembling the tripod joint AAR 2000......................................................................90
REAR SUSPENSION, DRIVE SHAFT.......................................................................................................94
REPAIRING REAR AXLE - DRUM BRAKE.........................................................................................................94
Removing and installing rear suspension.................................................................................................94
Summary of components of rear axle.......................................................................................................98
Replacing the rubber-metal bearing......................................................................................................102
Replacing the rubber-metal bearing - version 1..................................................................................102
Removing and installing shock absorber/spring....................................................................................122
Disassembling and assembling shock absorber.....................................................................................124
REPAIRING REAR AXLE - DISC BRAKE.........................................................................................................126
Removing and installing rear suspension...............................................................................................126
2
Summary of components of rear axle.....................................................................................................129
Replacing the rubber-metal bearing......................................................................................................134
Removing and installing shock absorber/spring....................................................................................154
Disassembling and assembling shock absorber.....................................................................................155
REPAIRING THE WHEEL BEARING................................................................................................................157
Repairing the wheel bearing, vehicles with front-wheel drive - drum brake.........................................157
Repairing the wheel bearing - disc brake...............................................................................................163
REPAIRING REAR AXLE (VEHICLES WITH FOUR-WHEEL DRIVE)..................................................................169
Rear axle with four-wheel drive - Overview...........................................................................................169
Coil spring and shock absorber on vehicles with four-wheel drive - Summary of components.............171
Removing and installing coil spring.......................................................................................................173
Removing and installing shock absorber...............................................................................................178
TRAILING ARM AND SUSPENSION ARM - SUMMARY OF COMPONENTS........................................................180
Pressing out and pressing in...................................................................................................................184
Removing and installing rubber-metal bearing for trailing arm...........................................................190
Removing and installing guide joint.......................................................................................................192
Removing and installing trailing arm.....................................................................................................197
Removing and installing suspension arm...............................................................................................202
SUMMARY OF COMPONENTS - ASSEMBLY CARRIER WITH FINAL DRIVE......................................................205
Removing and installing assembly carrier with final drive....................................................................207
Removing and installing rubber-metal bearing for assembly carrier....................................................212
Removing and installing rubber-metal bearing for final drive..............................................................214
REPAIRING DRIVE SHAFT.............................................................................................................................218
Removing and installing a drive shaft....................................................................................................218
Repairing drive shaft with CV joint........................................................................................................221
WHEELS, TYRES. AXLE ALIGN............................................................................................................227
VEHICLE ALIGNMENT..................................................................................................................................227
General points........................................................................................................................................227
Test conditions........................................................................................................................................228
Measurement preliminaries....................................................................................................................229
Chassis terms..........................................................................................................................................230
Nominal values for vehicle alignment....................................................................................................230
Checking the transversal inclination of the vehicle...............................................................................231
Checking the camber on the front axle, if necessary take the mean.......................................................232
Checking the camber on the rear axle....................................................................................................233
Checking the track on the rear axle, if necessary taking the mean/adjusting........................................234
Checking the track on the front axle, adjusting if necessary..................................................................235
Checking the left and right steering angle.............................................................................................236
Calculation of the misalignment on the rear axle..................................................................................237
WHEELS AND TYRES...................................................................................................................................238
General points........................................................................................................................................238
Disc wheel..............................................................................................................................................239
Light-alloy wheel....................................................................................................................................240
VEHICLES WITH TYRE REPAIR SET...............................................................................................................242
Tyre sealant.............................................................................................................................................243
3
Tyre disassembly.....................................................................................................................................244
Assembly of new tyres.............................................................................................................................245
Disposing of tyre sealant........................................................................................................................246
ABS, ADR, TCS, EDL, ESP........................................................................................................................247
ANTILOCK BRAKING SYSTEM (ABS) ITT MARK 20 IE..............................................................................247
Safety precautions, basic information on fault finding and on repairing ABS and ABS/EDL ITT Mark 20
IE............................................................................................................................................................247
Notes on repair work on ABS and ABS/EDL ITT Mark 20 IE................................................................248
Required technical information..............................................................................................................249
DISTINGUISHING FEATURES OF THE ABS ITT MARK 20 IE AND THE ABS/EDL ITT MARK 20 IE...........250
General Instructions...............................................................................................................................250
ABS ITT Mark 20 IE...............................................................................................................................251
ABS/EDL ITT Mark 20 IE......................................................................................................................252
Fitting position ABS or ABS/EDL ITT Mark 20 IE................................................................................253
SELF-DIAGNOSIS..........................................................................................................................................254
Self-diagnosis functions..........................................................................................................................254
Indication of faults by means of warning lights -K47- and -K14/33-.....................................................255
Vehicle fitted with ABS/EDL - EDL does not operate.............................................................................256
PERFORM SELF-DIAGNOSIS..........................................................................................................................257
Test requirements....................................................................................................................................257
Connecting vehicle system tester -V.A.G 1552- and selecting function..................................................258
Interrogating control unit version..........................................................................................................259
Overview of selectable functions............................................................................................................261
Interrogating fault memory....................................................................................................................262
Automatic test sequence.........................................................................................................................263
Fault table..............................................................................................................................................264
Erasing fault memory.............................................................................................................................271
Ending output.........................................................................................................................................272
Coding control unit.................................................................................................................................273
Reading measured value block...............................................................................................................275
Actuator diagnosis..................................................................................................................................278
Basic setting............................................................................................................................................283
ELECTRICAL TEST OF THE ABS AND ABS/EDL ITT MARK 20 IE.............................................................287
Test conditions........................................................................................................................................288
Multi-pin plug connection with contact assignment...............................................................................289
Overview of test steps.............................................................................................................................291
Test table.................................................................................................................................................292
ELECTRIC/ELECTRONIC COMPONENTS AND FITTING LOCATIONS ABS, ABS/EDL MARK 20.....................299
Removing and installing the hydraulic control unit and the bracket.....................................................302
Repairing the hydraulic control unit......................................................................................................309
Checking/removing and installing parts of the ABS system on the front axle........................................313
Checking/removing and installing parts of the ABS system on the rear axle (disc brake and drum brake)
- front-wheel drive..................................................................................................................................320
Removing and installing as well as adjusting brake light switch up to model year 1999......................327
Removing and installing as well as adjusting brake light switch as of model year 2000......................329
SUMMARY OF COMPONENTS OF HYDRAULIC CONTROL UNIT, BRAKE SERVO UNIT/MASTER BRAKE
CYLINDER FOR VEHICLES WITH ABS, ABS/EDL MARK 20.......................................................................330
4
SELF-DIAGNOSIS OF THE ABS/EDL FOR FOUR-WHEEL DRIVE VEHICLES WITH HALDEX COUPLING..........333
Interrogating control unit version..........................................................................................................334
Fault table for the ABS/EDL of four-wheel drive vehicles with Haldex coupling..................................335
Code ABS/EDL control unit....................................................................................................................336
Check longitudinal acceleration sender -G251-....................................................................................336
Checking the data BUS cable.................................................................................................................338
Initiating basic setting............................................................................................................................340
Switch off longitudinal acceleration sender -G251-..............................................................................340
Null balance of the longitudinal acceleration sender -G251-................................................................341
ELECTRICAL TEST OF THE ABS/EDL FOR FOUR-WHEEL DRIVE VEHICLES WITH HALDEX COUPLING........342
Test table.................................................................................................................................................343
ELECTRIC/ELECTRONIC COMPONENTS AND FITTING LOCATIONS (FOUR-WHEEL DRIVE).............................345
Removing and installing longitudinal acceleration sender -G251-.......................................................348
Checking/removing and installing parts of the ABS system on the rear axle (disc brake) - four-wheel
drive........................................................................................................................................................349
ANTILOCK BRAKING SYSTEM ABS/ EDL/ESP MARK 20...........................................................................354
Safety precautions, basic information on fault finding and on repairing...............................................354
Notes on repair work on ABS/EDL/ESP Mark 20..................................................................................354
DISTINGUISHING FEATURES OF THE ABS/EDL ITT MARK 20 IE AND THE ABS/EDL/ESP ITT MARK 20 IE
....................................................................................................................................................................355
ABS/EDL/ESP ITT Mark 20 IE..............................................................................................................356
Fitting position ABS/EDL/ESP ITT Mark 20 IE.....................................................................................357
SELF-DIAGNOSIS OF THE ABS/EDL/TCS/ESP MARK 20...........................................................................358
Description of the function.....................................................................................................................358
Indication of faults by means of warning lights -K47-, -K14/33- and -K155-.......................................359
Vehicle fitted with ABS/EDL/ESP - EDL does not operate.....................................................................363
ELECTRICAL TEST OF THE ABS/EDL/ESP ITT MARK 20 IE......................................................................364
Test conditions........................................................................................................................................365
Test table.................................................................................................................................................372
Test steps 1 - 20......................................................................................................................................373
Test steps 21 - 28....................................................................................................................................384
ELECTRIC/ELECTRONIC COMPONENTS AND FITTING LOCATIONS ABS/EDL/ESP MARK 20.......................393
Removing and installing the hydraulic control unit ABS/EDL/ESP and the bracket.............................398
Repairing the hydraulic control unit ABS/EDL/ESP..............................................................................406
Removing and installing parts of the ESP system..................................................................................415
Removing and installing as well as setting the brake light switch.........................................................422
CYLINDER FOR VEHICLES WITH ABS/EDL/ESP MARK 20.........................................................................423
ANTILOCK BRAKING SYSTEM (ABS) MK60...............................................................................................427
Safety precautions, basic information on fault finding and on repairing ABS and ABS/TCS/EDL MK 60
................................................................................................................................................................427
Notes on repair work on ABS and ABS/TCS/EDL MK 60......................................................................427
5
ABS and ABS/TCS/EDL..........................................................................................................................427
Fitting position ABS or ABS/TCS/EDL MK 60......................................................................................427
ELECTRIC/ELECTRONIC COMPONENTS AND FITTING LOCATIONS ABS/EDL/TCS MARK 60......................428
Removing and installing the hydraulic control unit and the bracket.....................................................431
Repairing the hydraulic control unit......................................................................................................437
CYLINDER ABS/EDL/TCS MARK 60.........................................................................................................443
ELECTRICAL TEST ABS/EDL/ TCS MARK 60............................................................................................445
Multi-pin plug connections with contact assignment for ABS, ABS/EDL/TCS......................................447
Test table.................................................................................................................................................450
ANTILOCK BRAKING SYSTEM ABS/ EDL/TCS/ESP MARK 60...................................................................457
Safety precautions, basic information on fault finding and on repairing...............................................457
Notes on repair work on ABS/EDL/TCS/ESP Mark 60..........................................................................457
ELECTRIC/ELECTRONIC COMPONENTS AND FITTING LOCATIONS ABS/EDL/TCS/ESP MARK 60 MY 02
....................................................................................................................................................................458
ELECTRIC/ELECTRONIC COMPONENTS AND FITTING LOCATIONS ABS/EDL/TCS/ESP MARK 60 MY 02
....................................................................................................................................................................462
DISTINGUISHING FEATURES ABS/EDL/TCS MARK 60 AND ABS/EDL/TCS/ ESP MARK 60....................466
Fitting position ABS/EDL/TCS/ESP Mark 60........................................................................................466
SELF-DIAGNOSIS OF THE ABS/EDL/TCS/ESP MARK 60...........................................................................467
Description of the function.....................................................................................................................467
Indication of faults by means of warning lights -K47-, -K14/33- and -K155-.......................................467
ELECTRICAL TEST ABS/EDL/TCS/ESP MARK 60.....................................................................................472
Test table.................................................................................................................................................478
BRAKE, BRAKE MECHANICS...............................................................................................................494
REPAIRING THE FRONT BRAKE..........................................................................................................494
Changing the brake pads of the front brake - Mounting instructions....................................................494
Repairing front brake, the floating caliper disc brake FS-III................................................................495
Removing and installing brake pads/brake caliper (FS III)...................................................................499
Repairing the front wheel brake, brake caliper FN -3...........................................................................502
REMOVING AND INSTALLING BRAKE PADS/BRAKE CALIPER FN 3..............................................................507
Removing and installing brake discs (FN 3)..........................................................................................512
REPAIRING REAR WHEEL BRAKE - FRONT WHEEL DRIVE (DRUM BRAKE)...................................................515
Replacing the brake shoes of the rear brake - Mounting instructions...................................................515
Removing and installing rear wheel brake.............................................................................................516
Resetting brake.......................................................................................................................................520
Repairing rear brake..............................................................................................................................521
6
Removing and installing brake shoes.....................................................................................................525
Setting the hand-brake (drum brake).....................................................................................................528
REPAIRING REAR WHEEL-BRAKE - FRONT-WHEEL DRIVE (DISC BRAKE).....................................................530
Changing the brake pads of the rear wheel disc brake - Mounting instructions...................................530
Removing and installing brake pads......................................................................................................536
Setting the hand-brake (disc brake).......................................................................................................539
REMOVING AND INSTALLING HAND-BRAKE CABLE (DRUM BRAKE)............................................................541
REMOVING AND INSTALLING HAND-BRAKE CABLE (DISC BRAKE)..............................................................543
HANDBRAKE LEVER - SUMMARY OF COMPONENTS....................................................................................545
REPAIRING REAR WHEEL-BRAKE - FOUR-WHEEL DRIVE (DISC BRAKE).......................................................547
Changing the brake pads of the rear wheel disc brake - Mounting instructions...................................547
Removing and installing brake pads......................................................................................................553
Setting the hand-brake............................................................................................................................557
REMOVE AND INSTALL HAND-BRAKE CABLE, FOUR-WHEEL DRIVE/DISC BRAKE........................................559
SUMMARY OF COMPONENTS OF FOOT CONTROLS, BRAKE PEDAL............................................................561
Assembly overview of the foot controls, brake pedal - LHD vehicles....................................................561
Assembly overview of the foot controls, brake pedal - RHD vehicles....................................................563
Separating the brake pedal from the brake servo unit and clipping......................................................566
Removing and installing brake pedal.....................................................................................................569
BRAKES, HYDRAULICS, REGULATOR, SERVO...............................................................................572
SUMMARY OF COMPONENTS: BRAKE SERVO UNIT/MASTER BRAKE CYLINDER FOR VEHICLES WITHOUT
ABS OR WITH ABS, ABS/EDL MARK 20..................................................................................................572
Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles without ABS or with
ABS, ABS/EDL Mark 20 - LHD vehicles................................................................................................572
Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles without ABS or with
ABS, ABS/EDL Mark 20 - RHD vehicles................................................................................................575
Removing and installing the master brake cylinder - LHD vehicles......................................................579
Removing and installing the master brake cylinder - RHD vehicles......................................................579
Check brake servo unit...........................................................................................................................579
Removing and installing the brake servo unit - LHD vehicles...............................................................579
Removing and installing the brake servo unit - RHD vehicles...............................................................579
Removing and installing the vacuum pump for the brake servo unit.....................................................579
REPAIRING THE FRONT BRAKE CALIPER, BRAKE CALIPER FS III.............................................................579
Summary of Components of Brake Caliper FS-III.................................................................................579
Removing and installing the front brake caliper piston.........................................................................579
REPAIRING THE FRONT BRAKE CALIPER, BRAKE CALIPER FN 3..................................................................579
Assembly overview of the brake caliper FN3.........................................................................................579
Removing and installing the front brake caliper piston.........................................................................579
REPAIRING THE REAR BRAKE CALIPER........................................................................................................579
Summary of components of the brake caliper........................................................................................579
Removing and installing the rear brake caliper piston..........................................................................579
Temporary filling of brake caliper......................................................................................................579
SUMMARY OF COMPONENTS OF BRAKE-POWER REGULATOR......................................................................579
INSPECTING AND ADJUSTING THE BRAKE-POWER REGULATOR...................................................................579
Adjusting values for the load-dependent brake-power regulator...........................................................579
7
BLEED BRAKE SYSTEM, VEHICLES WITH OR WITHOUT ABS OR ABS/EDL MARK 20 AND MARK 60........579
Bleeding brake system with brake filling and bleeding device for vehicles with Mark 20....................579
Bleeding the brake system without using the brake filling and bleeding device....................................579
Bleeding brake system with brake filling and bleeding device for vehicles with ABS Mark 60.............579
CHECKING THE MASTER BRAKE CYLINDER FOR TIGHTNESS.......................................................................579
SUMMARY OF COMPONENTS: BRAKE SERVO UNIT/MASTER BRAKE CYLINDER FOR VEHICLES WITH
ABS/EDL/ESP MARK 20...........................................................................................................................581
Removing and installing brake pressure sender -1--G201- and brake pressure sender -2--G214-.......584
Removing and installing the master brake cylinder - LHD vehicles......................................................586
Removing and installing the master brake cylinder - RHD vehicles......................................................589
Removing and installing the brake servo unit - LHD vehicles...............................................................592
Removing and installing the brake servo unit - RHD vehicles...............................................................596
Removing and installing the vacuum pump for the brake servo unit.....................................................599
SUMMARY OF COMPONENTS: BRAKE SERVO UNIT/MASTER BRAKE CYLINDER FOR VEHICLES WITH
ABS/EDL/TCS/ESP MARK 60...................................................................................................................599
Removing and installing brake pressure sender -1--G201-...................................................................602
Removing and installing master brake cylinder.....................................................................................602
Removing and installing brake servo unit..............................................................................................602
Removing and installing brake vacuum pump -V192-...........................................................................602
Testing brake vacuum pump -V192-.......................................................................................................603
STEERING...................................................................................................................................................604
STEERING COLUMN AND STEERING WHEEL WITH AIRBAG..........................................................................604
Check the steering column for damage..................................................................................................604
Removing and installing steering column..............................................................................................605
Removing and installing the ignition lock housing with the steering column mounted.........................618
SUMMARY OF COMPONENTS OF POWER-STEERING GEAR - LHD VEHICLES................................................621
Removing and installing hydraulic oil reservoir....................................................................................624
REMOVING AND INSTALLING THE POWER-STEERING GEAR - LHD VEHICLES.............................................626
Repairing power-steering gear (ZF)......................................................................................................634
Modified track rod ends..........................................................................................................................641
Modified track rods................................................................................................................................642
Disposing of the power-steering gear....................................................................................................643
Adjusting the power-steering gear (ZF).................................................................................................644
Check the hydraulic oil level of the power-assisted steering, top up if necessary.................................645
Draining, filling and bleeding the power-assisted steering system........................................................647
Checking the power steering system for leaks........................................................................................649
Power steering noises.............................................................................................................................651
SUMMARY OF COMPONENTS OF POWER-STEERING GEAR - RHD VEHICLES...............................................652
Removing and installing hydraulic oil reservoir....................................................................................656
Removing and installing the power-assisted steering gear - RHD vehicles...........................................658
Repairing power-steering gear (ZF) - RHD vehicles.............................................................................665
SUMMARY OF COMPONENTS: VANE PUMP FOR POWER-ASSISTED STEERING..............................................668
Summary of components for the vane pump located at the top and bottom...........................................668
PAS pressure switch................................................................................................................................671
Check the feed pressure of the vane pump..............................................................................................673
8
REMOVING AND INSTALLING VANE PUMP...................................................................................................680
Vehicles with vane pump located at the top............................................................................................681
Vehicles with vane pump located at the bottom......................................................................................686
Disposing of the vane pump...................................................................................................................691
Running gear
Chassis
Technical data
Chassis - Specified values
Nominal values front axle

Spring strut type axle (front- and four-wheel drive)
Standard chassis Sport chassis Rough road
1) 1)2)
suspension 3)
Chassis G06 G20 1GA G35 G04 1GB
G12 G30 1GG G85 G07 1GW
G13 G31 1GE G34
G14 G32 1GH G39
G15 G33 G40
0 10' 0 10' 0 10'
Overall track -adjustable-
Camber4) - 30' 30' - 33' 30' - 16' 30'
- 0 25' 30' 5)7) - -
- 0 28' 30' 1) - -
30' 30' 30'
Max. difference of the caster angles between left and
right side
Toe difference angle on turns of 20 of inside wheel 1 30' 20' 1 31' 20' 1 27' 20'
-not adjustable-
Toe difference angle on turns at full lock of inside 6 35' 6 40' 6 35'
wheel -not adjustable-
40 39 45' 40 45'
Max. wheel lock angle -not adjustable-
Caster angle -not adjustable- 7 40' 30' 8) 7 50' 30' 8) 7 15' 30' 8)
7 40' +30', -60' 7 50' +30', 7 15' +30', -60' 9)
9)
-60' 9)
8 23' 30' 5) - -
6)7)
8 30' - -
Max. difference between left and right side 30' 30' 30'
Comment: Technical data apply for the unladen weight of the vehicle ready for driving (full fuel tank and
water reservoir for the windscreen wiper washer system, spare wheel, tool kit, jack and without driver).
1)
Not valid for Octavia 4x4
2)
Values are also valid for Octavia RS vehicles
9
3)
Values are also valid for Octavia 4x4 vehicles
4)
It is possible to adjust the camber by shifting the assembly carrier. Note: The screws and washers of the
assembly carrier must always be replaced! After carrying out corrections of steering geometry, inspect
position of steering wheel and alter to correct position, if necessary.
5)
Only Service Mobil (Octavia 1.9 ltr./66 kW SLX, Octavia 1.8 ltr./92 kW SLX)
6)
Only Service Mobil (Octavia Combi 1.9 ltr./81 kW SLX)
7)
Only Service Mobil (Octavia 1.9 ltr./66 kW GLX)
8)
up to MY 2000
9)
as of MY 2001
Specified values rear axle - front-wheel drive
Twist-beam rear axle
Standard suspension Sport chassis 1) Rough road suspension
Chassis
PR Nos. are not displayed on the vehicle data sticker. The allocation of the
adjusting values to the relevant running gear occurs via the PR No. of the front axle
damping.
Overall track -not 20' 10' 30' 10' 15' 10'
2)
adjustable- 30' 15' 4)
- -
25' 15' 5) - -
6)
Camber -not adjustable- - 1 36' 20' - - 1 36' 20' 6)
- 1 27' 20' 7) - 1 27' 20' 7)
- 1 27' 20'
- 1 43' 20' 4) - -
- 1 35' 20' 5) - -
Max. difference 30' 30' 30'
between left and right
side
Max. misalignment of 20' 20' 20'
the rear axle3)
1)
Values are also valid for Octavia RS vehicles
2)
The mean of the individual track values can be taken by moving the mounting brackets
3)
The mean value of the misalignment can be taken by moving the rear axle body
4)
Only Service Mobil (Octavia 1.9 ltr./66 kW SLX, Octavia 1.8 ltr./92 kW SLX)
5)
Only Service Mobil (Octavia 1.9 ltr./66 kW GLX, Octavia Combi 1.9 ltr./81 kW SLX)
6)
up to 11.96
7)
as of 12.96
Specified values rear axle - four-wheel drive
Twist-beam rear axle
Rough road suspension
Chassis
PR Nos. are not displayed on the vehicle data sticker. The allocation of the
adjusting values to the relevant running gear occurs via the PR No. of the front
axle damping.
Overall track -not - - 15' 10'
adjustable-1)
Camber -not adjustable- - - -30' 20'
10
Max. difference between - - 30'
left and right side
Max. misalignment of the - - 20'
rear axle2)
1)
The mean of the individual track values of the rear axle can be taken by moving the mounting brackets
2)
The running direction of the rear axle can be corrected by moving the mounting brackets
Nominal values rear axle
Chassis denominations with PR numbers
Different chassis are offered as additional equipment. These chassis are identified by PR numbers.
The type of chassis is identified by a chassis PR number on the vehicle data sticker.
The vehicle data sticker is located at the rear left on the luggage compartment floor and in the Service
Schedule.
Example of a vehicle data sticker

In this example the vehicle is fitted with a
standard damping running gear 1GA -arrow-.
11
Steering
Model All
Type of steering Rack and pinion type steering system
Steering gear Power-steering gear
Steering-wheel turns from stop to stop 3,04
Steering wheel diameter (mm) 370
Overall ratio of the steering 15,60
Lubricant for gear racks Fluid grease for steering gear
TL 733
N 052 733 00
Part No.: AOF 063 000 04
(e.g. DEA ORNA F6 EPO)
Filling weight (g) 23 to 27
Maximum clearance between pressure plate and cover (mm): 0,05 to 0,1
Perm. axial force for the displacement of the gear rack (N) 250
Rotating force of the track rods from the rest position (N) 1 to 3,5
Denomination of the hydraulic oil Hydraulic oil
TL 52 146
N 052 146 00
Part No.: G 002 000
(e.g. PENTOSIN CHF 11S)
Hydraulic oil amount in the system (I) 0,7 ... 0.9 Itr.
12
Brakes
Brake variants and their assignment
Engine litre/k 1,4/44; 1,4/55 1,6/55 1,6/74; 1,6/75 1.9/50

W SDI
S = Manual gearbox
S - S - S A S -
A = Automatic gearbox
Master brake cylinder - mm 23,81
Brake servo unit - Inch Left-hand drive with and without ABS 10'' 8,5
right-hand drive with and without ABS: 7''/8''- 8,5
tandem
t Front disc brake:
Front brake caliper FS-III 3)
Front brake caliper, piston - mm 54,0
Front brake disc - mm 256,0
Brake disc, thickness mm 22,0
Brake disc, minimum thickness mm 19,0
Pad thickness with supporting plate mm 19,5
Minimum thickness without mm 2,0
supporting plate
t Rear disc brake:
Rear brake caliper, piston - mm 41,0
Rear brake disc - mm 239,0
supporting plate
t Drum brake
Brake drum - mm 230,0
Brake drum - maximum diameter mm 231,0
Wheel-brake cylinder 1) - mm 20,64 20,64 20,64 19,05 19,05 4)
Wheel-brake cylinder 2) - mm 20,64 20,64 20,64 20,64 20,64
Brake pad, width mm 32,0
Pad thickness without supporting shoe mm 5,5
supporting shoe
1)
Vehicles without ABS
2)
Vehicles with ABS
3)
Not valid for Taxi vehicles (identification F4E)
4)
For Octavia Combi: 20.64
Engine litre/k 1,8/132 1,9/74 1,9/96

W
S = Manual gearbox
S - S - S -
13
Brake servo unit - Inch Left-hand drive with and without ABS 10''
right-hand drive with and without ABS: 7''/8''-
tandem
t Front disc brake:
Front brake caliper FS-III 3)
Front brake caliper, piston - mm 54,0
Front brake disc - mm 256,0
Minimum thickness without supporting mm 2,0
plate
t Rear disc brake:
Rear brake caliper, piston - mm 41,0
Rear brake disc - mm 239,0
plate
t Drum brake
Brake drum - mm
Brake drum - maximum diameter mm
Wheel-brake cylinder 1) - mm
Wheel-brake cylinder 2) - mm
Lining thickness mm
Pad thickness without supporting shoe mm
Minimum thickness without supporting mm
shoe
1)
2)
Vehicles with ABS
Engine litre/k 1.9/66 TDI 1.9/81 TDI 1,8/92; 2,0/85 (82) 1,8/110
W
S = Manual gearbox
S A S - S A S A
Brake servo unit - Inch Left-hand drive with and without ABS 10''
right-hand drive with and without ABS: 7''/8''-
tandem
t Front disc brake:
Front brake caliper FS-III 3)5) FN 3 4)
Front brake caliper, piston - mm 54,0 54,0
Front brake disc - mm 280,0 288,0
Brake disc, thickness mm 22,0 25,0
14
Brake disc, minimum thickness mm 19,0 23,0
Pad thickness with supporting plate mm 19,5 19,5
Minimum thickness without supporting mm 2,0 2,0
plate
t Rear disc brake:
Rear brake caliper, piston - mm 38,0 8)
41,0 9)
Rear brake disc - mm 232,0 6) 232,0
239,0 7) 239,0 7)
plate
t Drum brake
Brake drum - mm 230,0
Brake drum - maximum diameter mm 231,0
Wheel-brake cylinder 1) - mm 20,64
Wheel-brake cylinder 2) - mm 20,64 20,64
Brake pad, width mm 32,0
Pad thickness without supporting shoe mm 5,5
shoe
1)
2)
Vehicles with ABS
3)
Not valid for Taxi vehicles (identification F4E)
4)
For Taxi vehicles (F4E) also 1.9/66; 2.0/85; 1.9/81
5)
For Taxi vehicles (F4E) also 1.4/44; 1.4/55; 1.6/55; 1.6/74; 1.6/75; 1.9/50
6)
Vehicles with ESP
7)
vehicles with four-wheel drive
8)
up to 07.98
9)
as of 08.98
15
Brake fluid
Classification N 052 766 ZO (USA standard FMVSS 571.116 DOT 4)

VW 501 14
Capacity of brake fluid l 0.49 Vehicles with rear drum brakes, without ABS
0.53 Vehicles with rear drum brakes, with ABS
0.57 Vehicles with rear disc brakes, with ABS
Change brake fluid - every 2 years
Wheels, Tyres
Wheel rims:
t Bolt hole circle diameter: 100 mm
t Centre hole diameter: 57 mm
t 5-hole fixing
t Tyre inflation pressures BookletOctavia I as well as sticker on the fuel-tank cap
Note
Only tyres of the same size and type may be fitted to the vehicle, however the same brand and tread
t pattern must always be fitted to wheels on the same axle. It is exceptionally allowed to use a different
tyre temporarily in the event of breakdown. Take into account a change in driving and braking behaviour.
t Use wheel bolts with spherical collar and a thread of M14 x 1.5 - tightening torque: 120 Nm.
t Only use authorised rims on the relevant vehicle.
When replacing rims always use wheel bolts that belong to these rims (different length and spherical cap
t
shape).
t Also observe the national legislation.
If winter tyres are used with a lower speed rating than the maximum permissible driving speed, it has to
t be pointed out with a sticker providing an additional note which must be fixed in the field of vision of
the driver.
The information given on the sticker determines the maximum permissible driving speed for the winter
t
tyres fitted, which must not be exceeded during the operation of the vehicle.
The note on the sticker can be replaced with the system installed in the vehicle for life (for example the
t
onboard computer) Operating instructions.
On vehicles with the tyre pressure inspection system, it must be adapted again after changing one or
t
several wheels Operating instructions.
Caution
Tyres that are more than 6 years old must only be used in case of emergency and while driving very
carefully.
Engine Wheel size 1) Light-alloy rim Steel rim Offset (mm) Snow chains permitted
yes no
175/80 R14 88 T, H - 6J x 14 H2 38 X -
1.4 ltr./44kW 195/65 R15 91 T, H, V 6J x 15 H2 6J x 15 H2 38 X -
1.4 ltr./55kW 43 - X
1.6 ltr./55 kW 205/60 R15 91 H 6.5J x 15 H2 -
1.9 ltr./50 kW 205/55 R16 91 H 6.5J x 16 H2 - 42 - X
16
205/55 R16 91 W 5,5J x 16 H2 - 36 X -
1.6ltr./74 kW 175/80 R14 88 H - 6J x 14 H2 38 X -
1.6 ltr./75 kW 195/65 R15 91 H, V 6J x 15 H2 6J x 15 H2 38 X -
205/60 R15 91 H 6.5J x 15 H2 - 43 - X
205/55 R16 91 H 6.5J x 16 H2 - 42 - X
205/55 R16 91 W 5,5J x 16 H2 - 36 X -
2.0 ltr./85 kW 195/65 R15 91 H, V 6J x 15 H2 6J x 15 H2 38 X -
205/60 R15 91 H 6.5J x 15 H2 - 43 - X
205/55 R16 91 H 6.5J x 16 H2 - 42 - X
205/55 R16 91 W 5,5J x 16 H2 - 36 X -
1,8 Itr./92 kW 195/65 R15 91 H, V 6J x15 H2 6Jx15 H2 38 X -
205/60 R15 91 H, V 6.5J x 15H2 - 43 - X
205/55 R16 91 H, V, W 6.5J x 16H2 - 42 - X
205/55 R16 91 W 5,5J x 16H2 - 36 X -
1.8 ltr./110 kW 195/65 R15 91 V 6J x 15 H2 6Jx15 H2 38 X -
205/55 R16 91 V, W 6.5J x 16H2 - 42 - X
205/60 R15 91 V 6.5J x 15H2 - 43 - X
205/55 R16 91 W 5,5J x 16H2 - 36 X -
1.8 ltr./132 kW 205/55 R16 91 W 6.5J x 16H2 6.5Jx16H2 42 - X
205/55 R16 91 W 5,5J x 16H2 - 36 X -
205/50R17 89W2) 7J x 17 H2 - 38 X -
1.9 ltr./66 kW TDI 195/65 R15 91 T, H, V 6J x15 H2 6Jx15 H2 38 X -
205/60 R15 91 H 6.5J x 15H2 - 43 - X
205/55 R16 91 H 6.5J x 16H2 - 42 - X
205/55 R16 91 W 5,5J x 16H2 - 36 X -
1.9 Itr./74 kW PDi 195/65 R15 91 V 6J x 15 H2 6Jx15 H2 38 X -
205/60 R15 91 V 6.5J x 15H2 - 43 - X
205/55 R16 91 V 6.5J x 16H2 - 42 - X
205/55 R16 91 W 5,5J x 16H2 - 36 X -
1.9 ltr./81 kW TDI 195/65 R15 91 H, V 6J x 15 H2 6Jx15 H2 38 X -
205/60 R15 91 H 6.5J x 15H2 - 43 - X
205/55 R16 91 H, V, W 6.5J x 16H2 - 42 - X
205/55 R16 91 W 5,5J x 16H2 - 36 X -
1.9 Itr./96 kW PDi 195/65 R15 91 V 6J x 15 H2 6Jx15 H2 38 X -
205/60 R15 91 V 6.5J x 15H2 - 43 - X
205/55 R16 91 V, W 6.5J x 16H2 - 42 - X
205/55 R16 91 W 5,5J x 16H2 - 36 X -
1)
Tyre inflation pressures BookletOctavia
2)
Not valid for Octavia Combi RS
Load rating-indexes (Load index): 88 = 560 kg 91 = 615 kg

89 = 580 kg
Speed symbols: T =190km/h H = 210km/h
V = 240 km/h W = 270 km/h
17
Tyre legend
Marking e.g. 175/80 R14 88 T Meaning
175/80 Tyre width (mm) section ratio between height - width (%)
R Tyre type (radial)
14 Rim diameter (inch)
88 Load rating-index
T Speed symbol
Production date
DOT...394 Manufactured during week 39 of 1994
( = denomination of the decade 1990...1999)
DOT...0300 Manufactured during week 3 of 2000
+ 03 = 3rd calendar week, 00 = year 2000)
18
Front suspension, drive shafts
Repairing front wheel suspension
I - Removing and installing assembly carrier, anti-roll bar, track control arm Chapter
II - Removing and installing wheel bearing, suspension strut, drive shaft, brake Chapter
l - Summary of components assembly carrier, anti-roll bar, track control arm
Note
When moving vehicles with drive shaft removed, it is advisable to install an external joint instead of the
t
drive shaft and tighten with a torque of 50 Nm otherwise the wheel bearing may get damaged.
Welding and straightening work is not allowed on the bearing and wheel control components of the
t
wheel suspension.
t Self-locking nuts must always be replaced.
t Always replace corroded self-locking nuts and screws.
19
1- track control arm
t removing and installing Chapter
t Oblong holes are not intended for camber adjustment!
2- 15 Nm + 90
3- Coupling rod
t coupling rods of the same version must be present on one axle
t Assignment Electronic Catalogue of Original Parts
4- 15 Nm + 90
t replace after each removal
5- Coupling rod
t only for anti-roll bars with a diameter of 23 mm
t replace with steel version
t coupling rods of the same version must be present on one axle
6- Front bearing for track control arm
t pressing in and pressing out Chapter
7- 70 Nm + 90
8- Pendulum support
9- 40 Nm + 90
20
10 - 40 Nm + 90
11 - 20 Nm + 90
12 - Assembly carrier
t The repair of the thread for the screwed connection of the front track control arm is not permissible!
13 - Self-locking nut
t M10 - 15 Nm + 90
t M12 - 90 Nm
14 - Anti-roll bar
t to remove and install lower assembly carrier
15 - Rubber bearing
16 - 25 Nm
17 - Clamp
18 - Coupling rod
t mount the spherical head with the long joint stub -A- (top) to the spring cap
t mount the spherical head with the short joint stub -B- (bottom) to the anti-roll bar
19 - Nut, 90 Nm
20 - Rubber-metal bearing
22 - 100 Nm + 90
23 - Rear bearing for track control arm
t Fitting position Anchor
t pressing in and pressing out Anchor
24 - 100 Nm + 90
25 - 70 Nm + 90
26 - Lock washer
27 - 20 Nm + 90
28 - Steering joint
t check Chapter
t Inspect rubber bellows for damage, if necessary replace
t removing and installing only in combination with the wheel bearing housing Chapter
mark fitting position before removal, set in the middle of the oblong hole when replacing the track control
t
arm and check track
29 - 20 Nm + 90
21
Removing and installing the track control arm
Special tools and workshop equipment required

t Extractor -MP 6-425-
t Supporting device -MP 9-200-
t Torque wrench, e.g. -V.A.G 1756-
Removing
Remove wheel trim cap, for light-alloy wheels remove the cap (pull-off hook in tool kit).
Raise the vehicle until the front axle is free of stress.
Slacken twelve-point nut.
Raise vehicle and remove wheel.
Release twelve-point nut.
Removing noise insulation Engine - Mechanics; Rep. gr.10
Only for vehicles with automatic gearbox:
Insert supporting device -MP 9-200- and
support engine/gearbox in this position.

For all vehicles:
Note
Mark installation position of bolts -1-, otherwise

the steering geometry must be checked.
Release screws -1-.
22
Push out the drive shaft. To do so position the
tool as shown in the fig.

Note
While pushing out the drive shaft make sure there

is sufficient clearance.
Unscrew screws -3-, if present, at the track
control arm.
Screw out screws -1- and -2-.
Remove the track control arm.
Only for vehicles with autom. gearbox
Release screws -4- for pendulum support.
Unscrew screws -5- and -6- for assembly
carrier.
Note
Release the screw -1- downwards by slightly

pressing the assembly carrier and take out the
wheel-bearing housing.
Install
(Valid for vehicles with manual and automatic
gearbox).
Remove possible corrosion in the thread/serration
of the outer joint.
Insert track control arm and secure.
Secure assembly carrier.
Moisten the serration of the wheel hub with oil.
Insert outer joint as far as possible into the
serration of the wheel hub.

Screw the steering joint and track control arm
with the new screws in the former positions.

Screw the pendulum support to the gearbox.
If necessary, screw the coupling rod with the
track control arm or with the suspension strut.

Moisten the contact surface of the twelve-point
nut as well as the serration and the thread of the
outer joint with oil and screw on new twelve-
point nut as far as possible.
Insert the outer joint into the wheel hub until
the outer joint rests in the wheel bearing.

Install noise insulation Engine,
Mechanics; Rep. gr.10.

23
Attach the wheel.
Lower vehicle, when doing so, ensure that the
wheels do not yet touch the ground.

Use new screws!
If the wheel bearings are loaded through the
vehicle's own weight, the wheel bearing will be
initially damaged. This shortens the life of the
wheel bearing.
Depress brake pedal (assistance of second
mechanic required).
Tighten new twelve-point nut to 225 Nm and
release by 1/2 a turn.

Torque wheel hub a further min. 90.
Tighten twelve-point nut:
Tightening torque:
50 Nm + 60.
Note
The torque wrench is recommended e.g. for

tightening the twelve-point nut -V.A.G 1756-.
Tightening torques:
Assembly carrier to body 100 Nm + 90
t Use new screws!
Steering joint to track control arm 20 Nm + 90
t Use new screws and new lock washer!
Pendulum support to gearbox 40 Nm + 90
t Use new screws!
Coupling rod to track control arm 15 Nm + 90
t Use new screws!
Pressing out and in the bearing for the track control arm

t Pressure plate -MP 3-406-
t Pipe section -MP 3-414-
24
t Pressure washer -MP 3-456-
t Assembly device -MP 5-402-
t Pressure spindle -MP 6-405-
t Base -MP 6-407-
t Pressure pipe -MP 6-408-
t Workshop press, e.g. -V.A.G 1290 A-
t acid-free lubricant, e.g. -G 294 421-
Press off front bearing for track control arm
Press in front bearing for track control arm

Insert bearing into pipe section -MP 3-414-.
Note
Use acid-free lubricant, e.g. -G 294 421-, when

pressing in the bearing. Under no circumstances
use grease or detergent.
25
Fitting position of rear bearing for track control
arm
One of the embossed arrows points to the
impression in the track control arm, the kidney-
shaped recess (-arrow A-) in the bearing points to
the centre of the vehicle.
Pressing out and in the rear bearing for the track

control arm
Pay attention to the fitting position when pressing
in Anchor.
Removing and installing assembly carrier

t Gearbox jack with adapter, e.g. -V.A.G 1383A- with -V.A.G 1359/2-
Removing
Remove wheel trim caps of the front wheels, for light-alloy wheels remove the caps (pull-off hook in
tool kit).
Slacken left and right twelve-point nut.
26
Raise vehicle and remove wheel.
Unscrew left and right twelve-point nut.
Remove noise insulation Engine - Mechanics; Rep. gr.10.
Note
Mark installation position of bolts -1-, otherwise the steering geometry must be checked.
Release screws -1-.
Press out left and right drive shaft. To do so
position the tool as shown in the fig.

Note

Separate left and right track control arm from
steering joint.
Swivel out the wheel-bearing housing with the
steering joint and support.
Release screws -1- and -2- and remove
pendulum support.
Release screws for power-steering gear -5-.
Unscrew nut -7- for coupling rod from anti-roll
bar.
Unscrew screws -6- for exhaust system.
Position the gearbox jack with adapter, e.g.
-V.A.G 1383/A- with -V.A.G. 1359/2-, under
the assembly carrier.
carrier.
Lower assembly carrier with gearbox jack.
Note
27
Ensure that the steering gear loosens from the
assembly carrier.
Support steering gear, if necessary clamp with
tensioning strap to the top.

Install
Before inserting the screws for the assembly
carrier, position the steering gear on the assembly
carrier and insert the screws for the steering gear.
The threaded bush -1- must fit in the hole of the

assembly carrier.
Further installation occurs in reverse order.
Tightening torques Chapter.
Once the steering gear has been installed it is then
important to check the position of the steering
wheel during a test drive.
If the vehicle drifts, a chassis alignment must be
performed.
Pressing out and in rubber-metal bearing

t Counterholder -MP 6-410-
t Workshop press, e.g. -V.A.G. 1290A-
t Gearbox jack with adapter, e.g. -V.A.G. 1383/A- with -V.A.G 1359/2-
t acid-free lubricant, e.g. -G 294 421 A1-.
Pressing out and in the rubber-metal bearings is only possible after removing the assembly carrier.
Removing and installing assembly carrier Chapter.
28
Pressing out the rubber-metal bearing
Pressing in rubber-metal bearing

Note
Coat rubber-metal bearing and assembly carrier

with acid-free lubricant before pressing them in,
e.g. -G 294 421 A1-. Under no circumstances use
grease or detergent.
II - Summary of components of the wheel bearing, suspension strut, drive shaft, brake
Note
t
Welding and straightening work is not allowed on the bearing and wheel control components of the front
t
wheel suspension.
t Always replace self-locking nuts.
29
1- Self-locking nut, 60 Nm
2- Stop
3- Suspension strut
t repairing Chapter
4- Drive shaft with inner CV joint
t repairing Chapter
5- Shim
6- Fillister head screw with internal serrations
t initially tighten to 10 Nm and subsequently tighten crosswise to final torque:
M8 = 20 Nm + 180
M10 = 50 Nm + 45
7- Drive shaft with inner tripod joint
t repairing Chapter
30
t initially tighten to 10 Nm and subsequently tighten crosswise to final torque:
M8 = 20 Nm + 90
M10 = 50 Nm + 45
9- Brake disc (FS-III)
t without marking for axial run-out
t with a fixing hole for the wheel hub
10 - Wheel screw, 120 Nm
11 - Self-locking twelve-point nut
t slacken and tighten Chapter
12 - 4 Nm
13 - Brake discs (FS-III)
14 - Brake caliper (FS-III)
Including for vehicles with engine up to 92 kW.
t do not release brake hose when working on the front wheel suspension
t tie up with wire or anything similar
t repairing Chapter
15 - Guide bolt (FS-III), 30 Nm
16 - Cap (FS-III)
17 - Brake disc (FN 3)
t with marking for maximum axial run-out
t with 5 fixing holes for the wheel hub
18 - Wheel hub with pulse rotor for wheel speed sensor
t with marking for minimum axial run-out
t only on vehicles with ABS
t pressing out Chapter
t installing Chapter
t Pull off the inner ring of the bearing Chapter
t Check axial run-out of pulse rotor Chapter
19 - Brake discs (FN-3)
20 - Retaining spring (FN-3)
21 - Brake carrier (FN-3)
22 - Brake caliper (FN-3)
Including for vehicles with engine as of 96 kW.
t do not release brake hose when working on the front wheel suspension
t tie up with wire or anything similar
t Removing and installing brake pads Chapter
t repairing Chapter
23 - Guide bolt (FN-3), 30 Nm
31
24 - Cap (FN-3)
25 - Screw with securing collar (FN-3), 124 Nm
t Clean ribbing on the underside
26 - Wheel-bearing housing
Including for vehicles with engine as of 96 kW.
t repairing Chapter
before pressing in the wheel bearing, coat the entire wheel bearing seat in the wheel bearing housing
t
evenly with -G 052 723 A2-
27 - Cover plate
28 - Self-locking nut, 50 Nm
29 - Steering joint
t check Chapter
t Inspect rubber bellows for damage, if necessary replace
Including for vehicles with engine up to 92 kW.
t repairing Chapter
before pressing in the wheel bearing, coat the entire wheel bearing seat in the wheel bearing housing
t
evenly with -G 052 723 A2-
31 - Self-locking nut, 20 Nm + 90
32 - Screw
33 - 8 Nm
34 - ABS wheel speed sensor
t insert with solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
t up to 05.98: 50 Nm + 90
t as of 06.98: 60 Nm + 90
36 - Track rod with track rod end
37 - 10 Nm
38 - Wheel bearing
t press out Chapter
t replace, is damaged when pressing out
The spare part is only delivered as a set wheel bearing with mounting parts (Pos. 11, 39, 38, 28, 31 and
t
35)
39 - Circlip
t pay attention to correct position Chapter
40 - Wheel hub without pulse rotor
t only on vehicles without ABS
32
t without marking for minimum axial run-out
t press out Chapter
t Pull off the inner ring of the bearing Chapter
Repairing wheel bearing housing

t Thrust plate -MP 3-467-
t Ring spanner SW 46 -MP 6-413-
t Assembly device -MP 6-414/1-
t Washer -MP 6-415-
t Washer -MP 6-416-
t Thrust piece -MP 6-418-
t Pipe -MP 6-419-
t Pressure pipe -MP 6-420-
t Socket wrench insert SW 21 -MP 6-427-
t Spreader -VAS 3424-
t Puller Kukko -V 176-
t Cross member Kukko 18-0
t Grease -G 052 723 A2- (molykote grease)
It is only possible to repair the wheel-bearing housing, by pressing out and in the wheel hub and the wheel
bearing, after removing the suspension strut and the wheel-bearing housing.
Remove and install suspension strut and wheel bearing housing Chapter.
33
Press the wheel hub out of the wheel bearing
Removing and installing circlip

Remove or replace circlip with commercially
available circlip pliers.

Note
t Replace.
When inserting, pay attention to the correct
t
position of the circlip.
Press the wheel bearing out of the wheel bearing

housing
34
Pull the inner ring of the bearing off the wheel
hub
Insert washer -MP 6-416- as shown.
Screw cross member Kukko 18-0 into washer
-MP 6-416-.
Position thrust plate -MP 3-467- onto wheel
hub and pull off the inner ring of the bearing by
turning the threaded spindle.
Press the wheel bearing into the wheel bearing

housing
-A- Wheel bearing
Before pressing in the wheel bearing, coat the
entire wheel bearing seat in the wheel bearing
housing evenly with -G 052 723 A2-.
Note
After pressing in the wheel bearing, the circlip

must be inserted Anchor.
Press the wheel hub into the wheel bearing

Note
When pressing in the wheel hub, ensure that the

t washer -MP 6-415- rests against the inner ring
of the bearing.
For wheel bearing housing and wheel hub on
vehicles including with engine as of 110 kW
t (brake FN-3) observe the assignment of the
wheel hub electronic catalogue of original
parts.
Wheel hubs with a 3 mm wide ink-jet marking
for marking the minimum axial run-out can also
be combined with brake discs without marking
t
of the maximum axial run-out. Then the
reduction of the overall axial run-out of the
brake FN 3 is not effective.
Inspecting the steering joint
35
Inspecting axial play
Pull the track control arm down with force and

push up again.
Inspecting radial play
Forcefully push the wheel

at the bottom towards the
inside and the outside.
Note
For these two tests no

t play may be felt or be
visible.
Observe the steering
t
joint during the tests.
Take into account
possible wheel bearing
t play or play in top
suspension strut
bearing.
Inspect rubber bellows
t for damage, if
necessary replace.
Removing and installing the steering joint

t Extractor Matra -V176-
Removing
It is only possible to remove the steering joint after removing the suspension strut and the wheel bearing
36
housing.
Remove and install suspension strut and wheel bearing housing Chapter.
Position the special tools as shown in the fig.
and slacken the hexagon nut.

-A- Torx screw -T 30-
Place the extractor as shown in the fig. and
push out the steering joint.

Install
Installation is carried out in the reverse order.
Note
Replace hexagon collar nut.
Tightening torques:
Steering joint to wheel-bearing housing 20 Nm + 90
Remove and install suspension strut and wheel bearing housing

t Extractor Matra -V176-
Removing
Remove wheel and raise vehicle.
37
Note
Release screws -1-.

Note

Press the track rod off the steering arm using

the extractor Matra -V176- (commercially
available).
Disconnect the plug -1- of the ABS wheel
speed sensor.
Remove the ABS wheel speed sensor cable
from the ties -arrows-.
38
Remove caps -2- and unscrew brake caliper.
Secure brake carrier with wire to body.

Remove the brake disc (the brake disc is
secured with a screw to the wheel hub).

If necessary, unscrew the coupling rod from the
suspension strut.
Unscrew the suspension strut on the body with
socket wrench insert -MP 6-427-.

Take out the suspension strut with the wheel
bearing housing.
Separate the suspension strut from the wheel

bearing housing
Insert the spreader -VAS 3424- as shown and
spread open the wheel bearing housing.

Remove the suspension strut.
Install
- Remove possible corrosion in the
thread/serration of the outer joint.
Insert the suspension strut with the wheel
bearing housing and secure it to the suspension
strut dome.
If necessary, secure the coupling rod to the
suspension strut.


Secure the brake caliper housing to the wheel
bearing housing.
39
Note
Tighten the FN-3 brakes at the wheel bearing

housing to 124 Nm.
Insert the cable of the ABS wheel speed sensor
into the brackets.

Mount the plug of the ABS wheel speed sensor.
- Moisten the contact surface of the twelve-point

Attach the wheel.

wheel bearing.
mechanic required).

Tightening torque:
50 Nm + 60
Note
A torque wrench is recommended for tightening

the twelve-point nut -V.A.G 1756-.
Tightening torques:
Suspension strut to suspension strut dome 60 Nm
Coupling rod to suspension strut 90 Nm
t Use new nuts!
40
t Use new nuts!
Brake caliper housing to wheel bearing housing 30 Nm
Repairing the suspension strut

t Spring tensioning device, e.g. -S 505 501 V- or -V.A.G 1752/1-
t Suspension strut support, e.g. -V.A.G 1752/2-
t Spring holder with protective lining, e.g. -V.A.G 1752/4-
1- Shock absorber with spring cap

t must be replaced completely
t can be replaced individually
t Inspecting the shock absorber Chapter
t disposing of Chapter
2- Stop buffer
3- Boot
4- Coil spring
t removing Fig.
t installing Fig.
41
t check colour coding
t The surface of the spring coil must not be damaged
t replace on both sides of the axle
t per axle only use coil springs of the same make
5- Spring cap
6- Bush
Only present on vehicles with rough road suspension (PR No. 1GB). This PR No. can be found on the
t
vehicle data sticker in the luggage compartment or in the Service Schedule Chapter
7- Axial grooved ball bearing
8- Suspension strut bearing
9- Collar nut, 60 Nm
t loosen and tighten
10 - Spring cap
11 - Collar nut, self-locking, 60 Nm
t replace after each removal Fig.
Removing the coil spring

Clamp the suspension strut support, e.g. -V.A.G
1752/2-, in the vice.

Clamp the suspension strut to the shock
absorber pipe in the suspension strut support.

Preload the coil spring with spring tensioning
device, e.g. -V.A.G 1752/1-, until the top spring
cap is released.

Pay attention to the correct seating of the coil
spring in the adapter, e.g. -V.A.G 1752/4--
arrow-.
42
Unscrew the collar nut from the piston rod
using the socket wrench insert -MP 6-427-, to
do so counterhold with Allen key.
Remove individual parts of the suspension strut
and the preloaded coil spring using the spring
tensioning device, e.g. -V.A.G 1752/1-.
Installing the coil spring

Position the preloaded coil spring with spring
tensioning device, e.g. -V.A.G 1752/1-, on the
bottom spring washer, to do so the spring coil
end must lie against the stop -arrow-.
Inspecting the shock absorber
43
Leaks on the shock absorbers
Minor oil leakage (sweating) on the piston rod
seal does not entail the replacement of the shock
absorber.
If an oil leak is visible (but blunt, dull, possibly
dried by dust) and does not propagate any further
than from the top shock-absorber plug (piston rod
seal) to the bottom spring cap -arrow-, the shock
absorber is deemed to be O.K.
Note
A slight oil leak is beneficial as the gasket is

lubricated and this increases the life time. This
applies for shock absorbers on the front as well as
the rear axle.
Noises on the shock absorbers
Attention must be drawn to the fact that in the
event of complaints about noise, the shock
absorbers are very often regarded as being the
source of noise.
Note
In the event of complaints about noises

interpreted as knocking or cracking noises,
always first perform a test drive with the
customer to determine where, when and how
these noises occur (preferably on a bumpy dry
road).
Inspect shock absorber without gas pressure
Defective shock absorbers become noticeable
while driving because of the knocking noises -
caused by wheel hopping - more specifically on
poor road and they must be replaced. The failure
is mainly caused by the loss of oil. The shock
absorber then compresses and/or expands in jolts.
It has an "idle travel" before taking effect.
Note
Shock absorbers are maintenance-free. It is not

possible to top up the shock absorber oil.
Inspect shock absorber with gas pressure
Defective shock absorbers with gas pressure are
also noticeable because of loud knocking noises
caused by wheel hopping and externally usually
exhibit considerable oil leakage.
Manual testing, as described below, can
determine if the shock absorber is damaged or
not:
Compress the shock absorber by hand.
While doing so, the piston rod can be moved
during the entire stroke time with a uniform
resistance and without jerking.
44
Release the piston rod. On sufficiently
pressurized shock absorbers it will
automatically return to its original position.
If this is not the case, the shock absorber need
not necessarily be replaced, as it will still
operate as a conventional shock absorber (see
instructions below).
Note
The absorbing function is still fully present

without gas pressure as long as the oil leakage
is not too important. However, the noise
t
intensity can deteriorate. On older vehicles it is
possible to continue using an operational yet
pressureless shock absorber without problem.
The spring shock absorbers with gas pressure
t
are only installed on the rear axle.
The gas pressure in the shock absorber
t improves the noise behaviour and the function
when driving over poor road surfaces.
Disposing of the shock absorber

t Pipe cutter, e.g. Stahlwille Express -150/3-
t Protective goggles
t Oil catching pan
WARNING
Cover the opening during degassing (gas pressure in as-new condition up to 2.5 MPa) and wear protective
googles.
Note
Defective shock absorbers with gas pressure are also noticeable because of loud knocking noises caused
t
by wheel hopping and externally usually exhibit considerable oil leakage.
The oils used in the shock absorbers do not contain any harmful substances. These oils can be disposed
t
of together with drained engine and gearbox oil.
Used oils (this concept refers to used engine and gear oils including ATF as well as mineral hydraulic
t oils), suitable for preparation must never be mixed with brake fluid, antifreeze agent, artificial resin or
thinners, chemicals etc.
t After "draining" the used parts must be allowed to drip adequately.
Drain front shock absorber
45
Clamp shock absorber in a vice.
Lever off protective cap with assembly lever or
anything similar and remove protective tube.

The protective cap and the protective tube are
only present on caulked shock absorbers.
Position a pipe cutter, e.g. Stahlwille Express
-150/3-, and cut through the outer pipe.

Pull the piston rod upwards and while doing so
grip the inner pipe with pipe pliers and press it
down in such a way that it remains in the outer
pipe when the piston rod is slowly pulled out.
Pull the piston rod out of the inner pipe.
Drain shock absorber.
Drain rear shock absorber (shock absorber with
gas pressure)
Clamp shock absorber vertically with the
piston rod pointing downwards in a vice.
Drill a hole in the outer pipe 3 mm -arrow
A-.
WARNING
Wear safety goggles.

Note
Gas will escape during drilling of the first pipe

wall (only for pressurized shock absorbers).
Drill further until the inner pipe has also been
drilled through (approx. 25 mm deep).
46
Drill a second hole (-arrow B-) 6 mm
through the inner pipe.

Hold the shock absorber over an oil catching
pan, move the piston rod several times up and
down over its entire stroke until no more oil

escapes.
Note
The shock absorber can also be opened with a

pipe cutter Anchor. First the shock absorber
must be depressurized by center drilling the outer
pipe (-arrow A-) previous fig. Anchor.
Removing and installing a drive shaft

Removing
Note
t The wheel bearing must not be loaded when the twelve-point nut is loose. At full load the wheel bearing
47
is initially damaged through the vehicle's own weight, thus shortening the life of the wheel bearing.
t
Assignment of the drive shaft and marking electronic catalogue of original parts.
Remove noise insulation Engine - Mechanics; Rep. gr.10.
Unscrew the drive shaft from the flange shaft/gearbox.
Note
Release screws -1-.

Note
While pushing out the drive shaft make sure

t
there is sufficient clearance.
The drive shaft must not hang down while
t being pressed out. Otherwise overstretching
will cause damage to the inner joint.
Remove the drive shaft.
Note
The following working step must only be

performed on vehicles with automatic gearbox.
48
Slacken screws of gearbox-pendulum support
-arrow- at assembly carrier.
Lever out the engine/gearbox assembly with a

tyre iron in direction of travel, at the same time
the drive shaft with tripod can be removed.
The -arrow- shows the direction of travel.
Install (vehicles with manual and automatic
gearbox)
- Remove possible corrosion in the
thread/serration of the outer joint.
Insert drive shaft.


Screw drive shaft onto flange shaft.
Screw the pendulum support to the assembly
carrier.
- Moisten the contact surface of the twelve-point

Install noise insulation Engine,

Attach the wheel.

wheel bearing.
mechanic required).

49
Tightening torque:
50 Nm + 60.
Note

Tightening torques:
Tighten drive shaft to flange shaft diagonally across in 2 steps (I and II)
I. 2nd
Screw M8 x 18 10 Nm 20 Nm + 90
Screw M8 x 48 10 Nm 20Nm + 180
t Use new screws!
Tighten drive shaft to flange shaft diagonally across in 2 steps (I and II)
I. 2nd
Screw M10 10 Nm 50 Nm + 45
t Use new screws!
Pendulum support to assembly carrier 20 Nm + 90
t Use new screws!
Repairing drive shaft
Repairing drive shaft with outer and inner CV joint

t Circlip pliers, e.g. -VW 161 A-
t Strutting bushing -MP 6-428-
t Tensioner -MP 6-429-
50
t Tensioning pliers, e.g. -V.A.G 1682-
t Sealant -D 454 300 A2-
Note
t Assignment of the drive shafts Electronic Catalogue of Original Parts.

t Grease joint if necessary, when replacing the joint boot.
t Spread the grease mass evenly in the joint boot - only on the side of the joint.
1- Right joint boot (tubular shaft)

t initially tighten to 10 Nm, subsequently tighten crosswise to final torque:
M8 x 48 = 20 Nm + 180
M10 x 52 = 50 Nm + 45
3- Shim
4- Open warm-type clamp
t replace
t tensioning Fig.
5- Joint boot for inner CV joint, 94 mm
t inspect for tears and chafing points
t remove from CV joint with drift
The fitting position of the joint boot for the inner CV joint for the right shaft is the same as the fitting
t
position of the joint boot for the outer CV joint 84mm Fig.
t before installation coat the inside of the cap with sealant -D 454 300 A2-
51
6- Joint boot for inner CV joint, 100 mm
t Fitting position for the left shaft Fig.
t Fitting position for the right shaft Fig.
t before installation coat the inside of the cap with sealant -D 454 300 A2-
7- Disc spring
t Fitting position Fig.
8- Inner CV joint
t pressing out Fig.
t pressing on Fig.
t grease Anchor
t check Chapter
9- Gasket
t The adherend on the inner CV joint must be free of grease and oil!
t replace
t Remove the protective foil from the gasket and stick it into the inner joint
10 - Circlip
t replace
t remove with circlip pliers, e.g. -VW 161 A-,
11 - Left drive shaft (solid shaft)
12 - Open warm-type clamp
t replace
t tensioning Fig.
13 - Joint boot for outer CV joint
t pay attention to different version: 84 mm, 90 mm
t The fitting position of the joint boot for the outer CV joint 90 mm for the left shaft Fig.
The fitting position of the joint boot for the outer CV joint 90 mm for the right shaft is determined by
t
the fitting position on the shaft, identical as Fig.
t The fitting position of the joint boot for the outer CV joint 84 mm for the left shaft Fig.
t The fitting position of the joint boot for the outer CV joint 84 mm for the right shaft Fig.
t replace
t tension with tensioning pliers, e.g. -V.A.G 1682-, Fig.
15 - Disc spring
16 - Thrust ring
17 - Circlip
t replace
t insert into the groove at the shaft
18 - Outer CV joint
52
t removing Fig.
t install: drive onto the shaft with a plastic hammer until the compressed circlip expands
t grease Anchor
t check Chapter
19 - 22 Nm
20 - M8 = 20 Nm, M10 = 33 Nm
21 - Protective housing
Repairing drive shaft with outer and inner CV joint VL 3700

t Chapter
Note

1- Outer CV joint
t removing Fig.
t grease Anchor
t check Chapter
2- Circlip
t replace
53
3- Thrust ring
4- Disc spring
t replace
t tension with tensioning pliers, e.g. -V.A.G 1682-, Fig.
6- Joint boot for outer CV joint
t Material: Hytrel (Polyelastomere)
t replace
t tensioning Fig.
8- Drive shaft
9- Joint boot for inner CV joint
t Material: Arnitel (Polyelastomere)
t replace
11 - Cover
t before installation coat the sealing surface of the cap with sealant -D 454 300 A2-
t The sealing surface must be free of oil and grease!
12 - Inner CV joint
t pressing out Fig.
t pressing on Fig.
t grease Anchor
t check Chapter
13 - Circlip
t replace
t remove with circlip pliers, e.g. -VW 161A-,
14 - Fillister head screw with internal serrations
t initially tighten to 10 Nm, subsequently tighten crosswise to final torque:
M8 x 48 = 20 Nm + 180
M10 x 52 = 50 Nm + 45
15 - Shim
16 - Gasket
54
t replace
t Remove the protective foil from the gasket and stick it into the inner joint
17 - Cover
t before installation coat the sealing surface of the cap with sealant -D 454 300 A2-
t The sealing surface must be free of oil and grease!
Grease quality and grease quantity

Note
The outer joints of the drive shaft are filled with:

Grease for operating at normal temperatures part no.: -G 052 738 A2-
Grease from the relevant repair kit
High temperature grease, part no.: -G 052 133 A2-, or part no.: -G 052 133 A3-
The inner joints of the drive shaft must only be filled with high temperature grease from the relevant
t repair kit or with grease part no.: -G 052 133 A2-, or part no.: -G 052 133 A3- electronic catalogue of
original parts
Grease quantity Anchor
Removing outer CV joint

Drive off joint boot with a drift.
Drive off the drive shaft with a strong blow of
a plastic hammer.
Pressing out the inner CV joint

Note
Support ball hub
55
Fitting position of the disc spring on the outer
joint (gearbox side)
-1- Disc spring
Fitting position of the disc spring and thrust ring

on the outer joint
-1- Disc spring
-2- Thrust ring
Pressing in the inner CV joint

Press the joint up to the stop.
Insert the circlip.
Note
Chamfer on inner diameter of the ball hub

(serration) must point towards the bearing collar
of the drive shaft.
56
Fitting position of the joint boot for the inner CV
joint 100 mm on the left shaft
Dimension -a- = 17 mm
Note
Mark the dimension -a- before installing the joint

boot on the drive shaft, e.g. using colour or
adhesive tape. Under no circumstances the
paintwork must be damaged with a sharp object.

joint 100 mm on the right shaft
The ventilation chamber -A- must be located on
the large pipe diameter.
-B- Ventilation hole.
Tighten the open warm-

type clamp on the outer
joint (at the large
diameter)
Note
In view of the hard

material (as opposed to
rubber) of the joint
boot, which requires
the use of a stainless
t steel open warm-type
clamp, the latter can
only be correctly
tightened with
tensioning pliers, e.g.
-V.A.G 1682-.
Tightening torque: 25
t
Nm.
t Use a torque wrench.
t Make sure the thread of
spindle -A- of the
57
tensioning pliers is
smooth. If necessary
grease with grease, e.g.
molykote MoS2.
If it is not smooth, e.g.
if the thread is dirty, the
necessary clamping
t force of the open
warm-type clamp is not
reached at the given
torque.
Position the tensioning
pliers, e.g. -V.A.G
1682-, as shown in the
fig. Make sure the
cutting edges of the

pliers are positioned in
the corners (-arrows B-)
of the open warm-type
clamp.
type clamp by turning
the spindle with a
torque wrench (do not
tilt the pliers during this
process).
-A- Spindle of tensioning
pliers
-B- Cutting edges of
tensioning pliers
Tighten the open warm-type clamp on the outer

joint (small diameter)
Position the tensioning pliers, e.g. -V.A.G
1682-, as shown in the fig. Make sure the
cutting edges of the pliers are positioned in the

corners (-arrows B-) of the open warm-type
clamp.
Tighten the open warm-type clamp by turning
the spindle with a torque wrench (do not tilt the
pliers during this process).
-A- Spindle of tensioning pliers
-B- Cutting edges of tensioning pliers
-C- Torque wrench
58
Tighten the open warm-type clamp on the inner
joint

corners (-arrows B-) of the open warm-type
clamp.
-A- Spindle of tensioning pliers
-B- Cutting edges of tensioning pliers
-C- Torque wrench
Fitting position of the joint boot for the outer CV

joint 90 mm on the left shaft
The sealing surface of the joint boot must rest up
to the stop on the shoulder of the shaft

joint 84 mm on the left and right shaft
On the drive shaft, 1 to 1 1/2 groove must be
visible
Note
The condition mentioned above regarding the

fitting position is also valid for the joint boot for
the inner CV joint 94 mm.
59
joint at the left and right shaft

joint at the left shaft

joint at the right shaft
Inspecting outer CV joint
Disassemble the joint to replace badly soiled grease or if the contact surfaces of the balls must be inspected
60
for wear and damage.
Removing
With an electric stylus or rubstone mark the

position of the ball hub relatively to the ball
cage and housing before disassembling -arrow-.
Rotate the ball hub and ball cage.
Remove the balls one after the other.
Turn the cage until the two rectangular cage
windows (-arrow-) rest on the joint part.

Remove cage with hub.
Turn the hub segment in the rectangular
window of the cage.

Swivel the hub out of the cage.
Note
The 6 balls of each joint belong to a tolerance

group. Inspect the axle studs, hub, cage and
balls for small depressions (pitting = point
erosion) and seizing marks. Load alteration
t
shocks indicate too much torsional clearance in
the joint, if this is the case replace the joint.
Smoothing and bearing marks do not justify a
joint replacement.
t Inspect the cage for tears.
Install
Press the required quantity of grease into the
joint part.
Grease quality and grease quantity Anchor.
Insert the cage with the hub in the joint part.
61
Note
The cage must be inserted in the correct position.

Press in opposite balls one after the other,
during this process observe the prior position of
the ball hub relatively to the ball cage and to the

joint part.
Insert new circlip in the groove of the shaft.
Spread any residual grease in the joint boot
Anchor.
Installing the joint boot Fig..
Inspecting inner CV joint
Disassemble the joint to replace badly soiled grease or if the contact surfaces of the balls must be inspected
for wear and damage.
Removing
Note
The ball hub and joint part are paired and must be marked before removal. Do not interchange the bearing
track assignment.
Swivel the ball hub
with the ball cage.

Press the ball hub and
the ball cage out of the
joint part -arrow-.
Press out the balls from
the cage.
62
Swivel the ball hub out
of the ball cage over
the ball bearing track
-arrows-.
Inspect the joint part,
ball hub, ball cage and
balls for small broken
out depressions (pitting
= point corrosion) and
seizing marks.
Note
Load alteration shocks

indicate too much
torsional clearance in the
joint. If this is the case,
replace the joint.
Smoothing and bearing
marks do not justify a
joint replacement.
Install
Insert the ball hub in

the ball cage over the
two chamfers. The
fitting location is
random. Press the balls
into the cage.
Insert the hub with
cage upright into the
joint part.
Note
63
When inserting make sure the greatest distance
-a- on the joint part is close to the short distance
t
-b- on the hub after it has been swivelled in
-arrow-.
t (serration) must point towards the largest
diameter of the joint part.
Swivel in the hub. To

do so swivel the hub
out of the cage -arrows-

until the balls are at
bearing track distance.
64
Lock the hub with the
balls into position by
exerting considerable
pressure on the cage
-arrow-.
Inspect the operation of
the inner CV joint
The CV joint is
correctly assembled if
the ball hub in the joint
l part can be rolled by
hand up and down the
entire linear
compensation.
Push the clamp and the
joint boot onto the
drive shaft.
Install drive shaft.
Press the specified
grease quantity for the
inner joint into the joint
from both sides.
Spread the prescribed
grease quantity evenly

into the joint boot.
Grease quality and grease
quantity Anchor.
Installing the joint boot
Fig..
Repairing drive shaft with inner tripod joint AAR 2900 and outer CV joint

t Tensioning pliers, e.g. -V.A.G 1275-, -V.A.G 1682-
t Circlip pliers (commercially available)
Note
The inner joints and the inner tripod joints must only be filled with high temperature grease from the
t
relevant repair kit electronic catalogue of original parts.
t Grease quantity for outer CV joint Anchor.
t Grease quantity for inner tripod joint Anchor.
Note
t Assignment of the drive shafts electronic catalogue of original parts

65
t On tripod joints only apply grease in the joint, never in the grease boot.

q inspect for tears and chafing points
q Assignment Electronic Catalogue of Original Parts
q replace
q tensioning Fig.
q replace
q tensioning Fig.
4- Drive shaft
5- Joint part
q grease Anchor
q replace after each removal
q initially tighten to 10 Nm, subsequently tighten crosswise to final torque:
M8 x 18 = 20 Nm + 90
M10 x 23 = 50 Nm + 45
7- Rollers
8- Tripod spider
q Chamfer -arrow- points towards the drive shaft serration
9- Circlip
q replace
66
q insert into the groove at the shaft
10 - O-ring seal
q no longer necessary for the assembly of the repaired drive shaft
11 - Oblong gasket ring
q The gasket ring belongs to the repair set
q The gasket ring is not fitted in the series, it is only necessary for the spare parts sector
12 - Cover
q is damaged when removing.
is no longer necessary for the assembly of the repaired drive shaft and is therefore only available as a
q
spare part
q for tripod joint
q always replace
14 - Joint boot for tripod joint
q for tripod joint
q always replace
q tensioning Anchor
16 - Disc spring
q Fitting position Fig.
17 - Thrust ring
18 - Circlip
q replace
19 - Outer CV joint
q must be replaced completely
q removing Fig.
q install: drive onto the shaft with a plastic hammer until the compressed circlip expands
q grease Anchor
q check Chapter
Disassembling and assembling the tripod joint AAR 2900

t Chapter
Anchor
Dismantling
Open warm-type clamp on joint part.
Open the open warm-type clamp at the drive shaft and push back the joint boot.
67
Clamp the drive shaft on the joint part in a vice
with protective jaws.

Lever off the cover with a screwdriver -1-.
Note
If the cover cannot be levered off, do likewise

t
on the opposite side of the cover.
The cover is damaged when levering off, it is
t no longer necessary for the assembly of the
repaired drive shaft.
Remove O-ring seal -arrow- from slot.

Mark fitting position of parts -1- ... -3- with the
help of lines.
-1- Joint part
-2- Tripod spider
-3- Drive shaft
Note
If the parts -1- ... -3- are not marked and if they
are not fitted in their original position again
t
when assembling, at a later stage this could
cause noises during driving.
t Use a waterproof marker for marking.
Hold the joint part and remove drive shaft from
the vice.
Ensure that the rollers do not topple off the tripod
spider and fall onto the floor!
Hold the drive shaft with the joint part
vertically and with the other hand gradually
push back the joint part.
68
Clamp the drive shaft in a vice with protective
jaws.
Mark the fitting position of the rollers -1- to the
tripod spider -2- with a felt-tip pen.

Remove rollers -1- and place them down on a
clean surface.
Remove circlip.
-1- Circlip pliers (commercially available)
Insert the drive shaft in the press.
69
Hold the drive shaft and press out of the tripod
spider.
Remove the joint part along with the joint boot
from the drive shaft.

Clean the drive shaft and the joint part.
Assembling together
Push a small open warm-type clamp for the
joint boot onto the drive shaft.

Insert the joint boot on the drive shaft.
Insert the joint part on the drive shaft.
Mounting the tripod spider
jaws.
Note
Chamfer -arrow- on the tripod spider must point

towards the drive shaft. Chamfer serves as an
assembly aid.
Position the tripod spider on the drive shaft
according to the marking and drive in up to the
stop.
Insert new circlip and pay attention to correct
position.
Fit the rollers corresponding to the markings
onto the tripod spider.

Remove the drive shaft from the vice.
Slide the joint part over the rollers and hold
down.
Clamp joint part into the vice.
70
Insert the oblong gasket ring -A- from the
repair set into the groove -arrow-.

Note
Direct sealing occurs between the tripod joint

(joint part) and the joint flange (on the gearbox
t
side) due to the oblong profile shape of the
gasket ring.
t The cover is no longer necessary.
Press the high temperature grease from the

repair set evenly into the tripod joint (on the
tripod spider side) -arrow A- and into the rear
side of the tripod joint -arrow B-.
Anchor
Installing the joint boot.
Tighten open warm-type clamp using pliers.
Tighten open warm-type clamp on the drive shaft

side with tensioning pliers e.g. -V.A.G 1275-.
71
Cover the tripod joint with a cardboard disc -A-
and adhesive tape -B-.

Note
Cover the tripod joint after the repair with a

self-cut, clean cardboard disc -A- and adhesive
tape -B-. This prevents the tripod spider, the
t joint part and the grease mass from clogging up
with dirt. In addition, this prevents that the
tripod joint is inadvertently pushed back when
installing the drive shaft.
The adhesive tape and the cardboard disc
should be removed only immediately before
t
screwing the drive shaft together with the joint
flange.
Repairing drive shaft with inner tripod joint AAR 2000 and outer CV joint

t Spacer sleeves -MP 3-458/2-
t Tensioning pliers, e.g. -V.A.G 1275-, -V.A.G 1682-
t Circlip pliers (commercially available)
Note
The inner joints and the inner tripod joints must only be filled with high temperature grease from the
t
relevant repair kit electronic catalogue of original parts.
t Grease quantity for outer CV joint Anchor.
t Grease quantity for inner tripod joint Anchor.
Note
t Assignment of the drive shafts electronic catalogue of original parts
72
t On tripod joints only apply grease in the joint, never in the grease boot.

q replace
q tensioning Fig.
q replace after each removal
q initially tighten to 10 Nm, subsequently tighten crosswise to final torque:
M8 x 28 = 20 Nm + 90
4- Shim
5- Joint part
q grease Anchor
6- Tripod spider with rollers
q Chamfer -arrow- points towards the drive shaft serration
7- Circlip
q replace
8- O-ring seal
q replace
9- Cover
q replace
73
q for tripod joint
q always replace
11 - Joint boot for tripod joint
12 - Drive shaft
q replace
q tensioning Fig.
14 - Disc spring
15 - Thrust ring
16 - Circlip
q replace
17 - Outer CV joint
q must be replaced completely
q removing Fig.
q install: drive onto the shaft with a plastic hammer until the compressed circlip expands
q grease Anchor
q check Chapter
Disassembling and assembling the tripod joint AAR 2000

t Chapter
Anchor
Dismantling
Open warm-type clamp on joint part.
Push back the joint boot.
74
Straighten the metal tabs -arrows- with a
screwdriver and lever off cover.
Remove O-ring seal -arrow- from slot.

Mark fitting position of parts -1- ... -3- with the
help of lines.
-1- Joint part
-2- Tripod spider
-3- Drive shaft
Note
If the parts -1- ... -3- are not marked and if they
are not fitted in their original position again
t
when assembling, at a later stage this could
cause noises during driving.
t Use a waterproof marker for marking.
Hold the joint part and remove drive shaft from
the vice.
75
jaws.
Remove circlip.
-1- Circlip pliers (commercially available)
Insert the drive shaft in the press.
Hold the drive shaft and push tripod spider off
the drive shaft.

Remove the tripod spider with rollers and lay
aside on a clean surface.

Remove the joint part from the drive shaft.
Remove the joint boot from the drive shaft.
Clean the drive shaft and the joint part.
Assembling together
Insert the joint boot on the drive shaft.
Insert the joint part on the drive shaft.
Install tripod joint
Note
Chamfer on the tripod spider must point towards

the drive shaft. Chamfer serves as an assembly
aid.
76
Position the tripod spider on the drive shaft
according to the marking and drive in up to the
stop.
Insert new circlip and pay attention to correct
position.
Slide the joint part over the rollers and hold
down.
Remove the drive shaft from the special tool
and clamp in the vice.
Press the high temperature grease from the

repair set evenly into the tripod joint (on the
tripod spider side) -arrow A- and into the rear
side of the tripod joint -arrow B-.
Anchor
Installing the joint boot.
Note
The bead in the joint boot must fit into the groove
of the joint part.
Remove drive shaft from the vice and clamp
the joint part.
77
Insert new gasket ring -arrow- from the repair
kit in the groove.

Fit the new cover on the joint part.
Note
The bores of the cover and joint part must be

flush.
Tighten open warm-type clamp using pliers.
Grease quantity
Outer joint Total quantity of Inner joint mm Total quantity of of which in

mm grease (g) grease (g)
Spread evenly in the Joint Joint boot
joint (g) (g)
94 (synchronous
81 90 90 45 45
running) 1)
100 (synchronous
90 110 120 60 60
running) 1)
90 110 108 (tripod) 1) 110 110 _
90 110 124 (tripod) 1) 140 140 _
100 (synchronous
98 130 190 190 _
running) 2)
1)
Valid for all vehicles, except 1.9 ltr./74 kW PD and 1.9 ltr./96 kW PD engines.
2)
Valid for vehicles with 1.9 ltr./74 kW PD and 1.9 ltr./96 kW PD engines.
Grease quality - outer CV joint
The outer CV joints can be filled with the following grease qualities:
t Grease for operating at normal temperatures, part no.: -G 052 738 A2-
t Grease from the relevant repair kit
t High temperature grease, part no.: -G 052 133 A2-, or part no.: -G 052 133 A3-
Grease quality - inner CV joint
The inner CV joints can be filled with the following grease qualities:
t Grease from the relevant repair kit
t High temperature grease, part no.: -G 052 133 A2-, or part no.: -G 052 133 A3-
Note
t -G 052 133 A2- Can with a grease quantity of 90 g

t -G 052 133 A3- Can with a grease quantity of 120 g
t Spread the quantity of grease for the joint evenly in the joint on the left and right.
t Spread the quantity of grease for the joint boot evenly in the joint boot - only on the side of the joint.
Rear suspension, drive shaft
78
Repairing rear axle - drum brake
Removing and installing rear suspension

t Tester for brake-power regulator, e.g. -V.A.G 1310-
t Gearbox jack with adapter, e.g. -V.A.G 1383 A- with -V.A.G 1359/2-
t Brake filling and bleeding device, e.g. -VAS 5234-
t Remove plugs for brake line
t Brake fluid Chapter
t Assembly paste -G 052 150 A2-
Removing
Remove wheels.
Release the hand-brake.
Note
Do not slacken the mounting bracket on body for the removal of the rear axle, otherwise the overall track
of the rear axle must be checked, adjusted if necessary.
Remove the screws -1- while the vehicle is

standing on its wheels. To do so, raise the
vehicle if necessary until the screws can be

reached.
Raise the vehicle to the height required for
installation in order to relieve tension from coil
spring.
Tilt the rear centre console, if necessary
remove Body Work; Rep. gr.68
79
Release adjusting nut -arrow-.
Remove the hand-brake cables -1- from the
hand-brake lever.
Pull hand-brake cables out of guide tubes.
Unclip brake cables -arrows-.

Detach retaining clips -2- from brake hose
fixture.
Separate brake lines.
Note
Seal lines with plugs.

Unplug connectors from the wheel speed
sensors.
Unclip the wheel speed sensor cable from the
bracket.
Only on vehicles fitted with brake-power
regulator (vehicles without ABS):
80
Unscrew bolt -1- of the brake-power regulator.
Valid for all vehicles:
Support the rear axle with gearbox jack with
adapter, e.g. -V.A.G 1383A- with -V.A.G
1359/2-.
Unscrew bolt -1- of the brake-power regulator.

Install
Before inserting the rear axle, grease the
kidney-shaped cavities of the rubber-metal
bearings with assembly paste -G 052 150 A2-.
Note
When tightening the screw of the rubber-metal

t bearing, the axle body must be in the horizontal
position (unladen condition).
When installing the hand brake cables, pay
t attention to the correct fitting position
Chapter.
Bleeding Brake System Chapter.
If fitted, inspect the load-sensitive brake
pressure regulator and set if necessary
Chapter.
performed.
Note
After slackening or changing the mounting

bracket, check the overall track of the rear axle,
adjust if necessary.
Tightening torques:
Shock absorber to body 30 Nm + 90
t Use new screws!
Rear suspension to bearing bracket 45 Nm + 90
Pipe screws, screws to brake lines 14 Nm
81
Summary of components of rear axle
Note
t Welding and straightening on axle body and axle studs not allowed.
t Always replace the self-locking nuts and screws.
t Pipe screws of brake hoses are tightened to a tightening torque of 14 Nm.
1- Wheel screw, 120 Nm

2- 4 Nm
3- Brake disc
t reset brake before removing the brake drum
4- Cap
t press off Fig.
t inserting Fig.
5- Self-locking twelve-point nut 70 Nm +40
6- Wheel hub with wheel bearing and pulse rotor
t The wheel bearing and the wheel hub are fitted together in one housing
82
this component is maintenance-free and requires no clearance adjustment; adjustment as well as repair
t
work are not possible
7- Wheel hub with wheel bearing without pulse rotor
t
8- 50 Nm + 60
9- Brake carrier with brake shoe
10 - Holder for hand-brake cable
t replace
11 - Hand-brake cable
13 - Self-locking screw, 30 Nm + 90
if the thread of the weld nut is damaged, it can be repaired using Heli-Coli threaded insert; while paying
t
attention to the fitting instructions of the manufacturer
t the rework of the thread for the weld nut is permissible on maximum 2 screw points per vehicle side
14 - 45 Nm + 90
t insert from the outside of the vehicle
t when tightening the screw, the axle body must be in the horizontal position (unladen condition)
15 - Mount for rear axle
t check the overall track of the rear axle after installation and adjust if necessary
t avoid slackening in order to remove the rear axle
18 - Socket nut
19 - Brake-power regulator
t testing and adjusting Chapter
20 - 20 Nm
21 - 16 Nm
22 - 20 Nm + 45
23 - Balancing weight
24 - Axle body
t The locating face and the threaded holes for axle studs must be free from enamel and dirt
26 - 8 Nm
27 - bottom base
28 - Coil spring
83
t check for paint damage, if necessary eliminate paint damage
t only use helical springs of the same make on the rear axle
29 - top base
t installing Anchor
30 - 40 Nm + 90
t insert from the inside of the vehicle
t when tightening, take the installation angle of the rear axle to the shock absorber into account Fig.
While the vehicle is standing on its wheels, load the luggage compartment with approx. 100 kg and
t
tighten the screw
if thread of the weld nut is damaged, it can be repaired using Heli-Coli threaded insert; while paying
t
attention to the notes of the manufacturer
t the rework of the thread for the weld nut is permissible on maximum 1 screw point per vehicle side
32 - Shock absorber
t only use helical springs of the same make on the rear axle
Note
Shock absorbers are not to be repaired.

34 - Brake line
35 - Axle stud
t Straightening work is not allowed!
t Re-cutting the thread is not allowed
36 - Protection against stones
37 - Fixing element for protection against stones
t Protection against stones included in the scope of delivery
84
Installation angle of rear axle/shock absorber
1- Shock absorber
- approx. 104
85
Replacing the rubber-metal bearing
Replacing the rubber-metal bearing - version 1

t Assembly device -MP5-400/1-
t Assembly device (screw) -MP5-401/2-
t Assembly device (nut) -MP5-401/3-
t Assembly device (bearing) -MP5-402-
t Pipe -T10263/6-
t Engine/gearbox jack with adapter, e.g. -V.A.G. 1383/A- with -V.A.G. 1359/2-
Removing:
Raise vehicle and remove rear wheels.
Unscrew screws of front wheelhouse liners on both vehicle sides Body Work; Rep. gr.66.
Unhook handbrake cable from the holders
-arrows- (on both vehicle sides).
Release the clamps -arrow A- for attaching the

brake lines from the brake line holders (on both
vehicle sides).
86
Remove the screw -1- from the brake line
holder on the right vehicle side.

Unhook the brake lines from the line holders.
Do not separate the brake lines.

Vehicles with ABS
Unhook the ABS line from the clips.
Vehicles fitted with load-sensitive brake pressure

regulator (vehicles without ABS)
Release screw -1-.
Continued for all vehicles
Insert wooden insert -A- into the adapter e.g.
-V.A.G 1359/2-
Support the axle with engine/gearbox jack with
adapter.
Vehicles with fixing screws mounted on the
outside
87
Unscrew the nuts of the fixing screws -1- from
the axle.
Remove fixing screws -1- from the axle.
inside
Remove the screws -2- of the bearing bracket

for the axle on the right vehicle side from the
body.
Note
Before removing the screws of the bearing

brackets for the axle, mark the position of the
bearing bracket on the body.
Remove the fixing screw -1- for the axle on the
left vehicle side from the bearing bracket for
the axle.
Slightly lower the rear axle out of the bearing
brackets so that the brake line is not damaged.

right vehicle side from the bearing bracket for
the axle.
Remove the bearing bracket from the axle.
Secure axle e.g with wire to body.
Position assembly devices, as shown, and pull

the rubber-metal bearing -1- out of the axle
body -2-.
Note
88
The pipe -T10263/6- must be installed on the
rubber-metal bearing in such a way that the
t
contact surface of the pipe -1- rests evenly
against the rubber-metal bearing.
Cut off the rubber edge in the contact point e.g
with a sharp knife so that the pipe cutout
t
-arrow- rests fully on the plastic
shoulder/rubber-metal bearing.
When pulling out the rubber-metal bearing, the
plastic shoulder/rubber-metal bearing breaks
t
off. In case of breakage, a loud crack can be
heard.
Pull out rubber-metal bearing by turning the
assembly device (nut) -MP5-401/3-.

Counterhold the assembly devices by hand
when completing the pull-out process.

Remove assembly devices and unscrew
Clamp the pipe -T10263/6- in the vice, as
shown in the fig.

Remove the rubber-metal bearing from the pipe
-T10263/6-, for example using a screwdriver,
drive out with a hammer if necessary.
Installing:
89
Fasten rubber-metal bearing -1- with assembly
devices and nut -2- and insert into the axle
body -3-.
Pay attention to the correct fitting position of
the rubber-metal bearing.
Fitting position of the rubber-metal bearing

Align orientation nubs -1- or orientation bead
-2- to edge of track control arm -3--arrow-.
90
Insert the rubber-metal bearing -1- by turning
the nut -MP 5-401/3- up to the stop in the axle
body -2-.
Check the fitting position of the rubber-metal
bearing.
Grease the kidney-shaped cavities of the
rubber-metal bearing with assembly paste
-G052 150 A2-.
outside
Carefully raise the rear axle so that the rubber-
metal bearing engages in the bearing brackets
for the axle.
Insert the new fixing screws -1- into the
bearing brackets for the axle.

Screw new nuts onto the fixing screws -1- for
bearing brackets of the rear axle and tighten.

inside
Position the bearing bracket for the axle on the
right vehicle side on the rubber-metal bearing.
Insert a new fixing screw -1- from the inside

into the bearing bracket for the axle on the right
vehicle side.
metal bearing engages on the left vehicle side
in the bearing bracket for the axle.
Ensure that the bearing bracket for the axle on
the right vehicle side rests at the same time
against the body in the marked position.
Screw the new fixing screws -2- of the bearing
bracket for the axle on the right vehicle side
into the body and tighten.
Note
When tightening the rubber-metal bearing screws

and nuts, the axle body must be in the unladen
condition (unladen weight position).
Vehicles with ABS
Hook on the ABS line in the clips.
91
Screw in the screw -1-.

Inspecting or adjusting the brake-power
regulator Chapter.
Install the screw -1- for the brake line holder on
the right vehicle side.

Hook on the brake lines in the line holders.
Push clamps -arrow A- into the brake hose
fixtures (on both vehicle sides).

Note

attention to the correct fitting position
Chapter.
92
Hook hand brake cables into the holders

Screw in screws of front wheelhouse liners on
both vehicle sides Body Work; Rep. gr.66.

Attach the wheels.
Perform chassis alignment Chapter.
Perform a test drive.
Check the steering wheel position during the
test drive.
Caution
If after the test drive and with the front wheels

pointing straight ahead the steering wheel is off
straight, perform a chassis alignment Chapter.
Tightening torque:
Rear axle to bearing bracket for axle 45 Nm + 90
t Use new screws and nuts!
t Tighten in unladen weight position
Bracket of rear axle to structure 30 Nm + 90
t Use new screws!
t Install in the marked position
Brake line holder to vehicle body 16 Nm
Screw for brake-power regulator 16 Nm

t Assembly device (nut) -T10254/4-
t Assembly device (screw) -T10254/5-
t Pipe -T10263/6-
t Hydraulic cylinder -VAS 6178-
t Foot pump -VAS 6179-
Removing:
93

vehicle sides).


Vehicles with ABS
94
Release screw -1-.
-V.A.G 1359/2-
adapter.
outside
the axle.
inside
95
body.
Note

the axle.

the axle.
Connect hydraulic line -1- of hydraulic pump

-VAS 6179- with quick coupling to hydraulic
cylinder -VAS 6178-.
Connect compressed air supply -2- with quick
coupling to hydraulic pump -VAS 6179-.
Position assembly devices, as shown, screw
together and counterhold by hand.

Note
96
t
t
t
heard.
Carefully depress the pedal of the hydraulic
pump -VAS 6179--arrow A-.

The hydraulic cylinder -VAS 6178- is therefore
activated.
Pull the rubber-metal bearing -1- out of the
axle body -2-.

97
pump -VAS 6179--arrow B-.

While doing so, the hydraulic cylinder -VAS
6178- returns to the initial position.
assembly device (nut) -T10254/4-.
shown in the fig.

Installing:
98

1- Rubber-metal bearing
2- Axle body


99
activated.
Insert the rubber-metal bearing -1- up to the
stop into the axle body -2-.

bearing.


-G052 150 A2-.
outside
for the axle.
100


inside

vehicle side.
Note

Vehicles with ABS
101
regulator Chapter.


Note

Chapter.
102


Attach the wheels.
test drive.
Caution

Tightening torque:
t Use new screws!
Removing and installing shock absorber/spring

Note
t The coil spring does not have to be removed in order to remove the shock absorber.
t The shock absorber does not have to be removed in order to remove the coil spring.
Remove the shock absorber
Raise the relevant side of the axle body with the gearbox jack.
103
Screw out screws -1- and -2- and take out
shock absorber.
Remove spring
Remove wheel trim cap, for light-alloy wheels
remove the cap (pull-off hook in tool kit).

Pull the wheel speed sensor cable out of the
supports.
Raise the relevant side of the axle body with
the gearbox jack.

Release screw -2-.
Lower the gearbox jack and remove the helical
spring.
Install
Note
Make sure that the top base (rubber) for the

t spring is correctly fitted when inserting it into
the support of the body.
t Pay attention to colour coding.
The bottom short circuit in coil must always
t
point to the centre of the vehicle.
The beginning of the spring -arrow- must be
positioned at the stop at the top of the base.

Tightening torques:
Chapter.
104
Disassembling and assembling shock absorber
1- Shock absorber
Note
The shock absorbers must not be disassembled and repaired.

2- Protective cap
3- Protective tube
4- Stop buffer
5- Top shock absorber bushing
6- Self-locking screw, 25 Nm
t counterhold the piston rod of the shock absorber in order to slacken and tighten the nut
7- Protective cap
105
Repairing rear axle - disc brake
Removing and installing rear suspension

t Remove plugs for brake line
Removing:
Note
Do not slacken the bracket for bonded rubber bush on body for the removal of the rear axle, otherwise the
overall track of the rear axle must be checked, adjusted if necessary.
Remove the screws -1- while the vehicle is

standing on its wheels. To do so, raise the
vehicle if necessary until the screws can be

reached.
Raise the vehicle to the height required for
installation in order to relieve tension from coil
spring.
Remove wheels.
106
Unclip brake cables -arrows-.
Detach retaining clips -2- from brake hose
fixture.
Separate brake line.
Note
Seal lines with plugs.
Unscrew the fixing screws -A- of the brake

caliper housing and secure the brake caliper
housing with wire to the body.
Unplug connectors from the wheel speed
sensors.
Unclip the speed sensor cable from the
brackets.
Support the rear axle with gearbox jack with
adapter, e.g. -V.A.G 1383 A- with -V.A.G
1359/2-.
Release the hexagon screws -1- of the rubber-
metal bearing and remove the rear axle.

Install
Before inserting the rear axle, grease the
kidney-shaped cavities of the rubber-metal
bearings with assembly paste -G 052 150 A2-.
Note
When tightening the screw of the rubber-metal

t bearing, the axle body must be in the horizontal
position (unladen condition).
t attention to the correct fitting position
Chapter.
performed.
107
Note
After slackening or changing the mounting

bracket, check the overall track of the rear axle,
adjust if necessary.
Tightening torques:
Shock absorber to body 30 Nm + 90
t Use new screws!
Rear suspension to bearing bracket 45 Nm + 90
Pipe screws to brake lines 14 Nm
Fixing screws for brake caliper 30 Nm + 30
Summary of components of rear axle
Note
t Welding and straightening on axle body and axle studs not allowed.
t Pipe screws of brake hoses are tightened to a tightening torque of 14 Nm.
108
2- 4 Nm
3- Brake disc
4- Cap
t press off Chapter, - Pos. 5
t drive in Chapter, - Pos. 5
109
t
7- 30 Nm + 90
8- Cover plate
9- Holder for hand-brake cable
t replace
11 - 45 Nm + 90
t when tightening the screw, the axle body must be in the horizontal position (unladen condition)
t
t the rework of the thread for the weld nut is permissible on maximum 2 screw points per axle
t avoid slackening in order to remove the rear axle
17 - 20 Nm + 45
18 - Balancing weight
20 - 8 Nm
21 - Axle body
t The locating face and the threaded holes for axle studs must be free from enamel and dirt
22 - bottom base
23 - Coil spring
t per rear axle only use helical springs of the same make
24 - top base
t installing Anchor
25 - 40 Nm + 90
t when tightening, take the installation angle of the rear axle to the shock absorber into account Fig.
110
While the vehicle is standing on its wheels, load the luggage compartment with approx. 100 kg and
t
tighten the screw
t
t the rework of the thread for the weld nut is permissible on maximum 2 screw points per axle
27 - Shock absorber
t per rear axle only use shock absorbers of the same make
Note
Shock absorbers are not to be repaired.

29 - Axle stud
30 - Protection against stones
31 - Fixing element for protection against stones
t Protection against stones included in the scope of delivery
32 - Brake line
33 - 30 Nm + 30
34 - Brake caliper
t repairing Chapter
111
Installation angle of rear axle/shock absorber
1- Shock absorber
- approx. 104
112
Replacing the rubber-metal bearing

t Assembly device (screw) -MP5-401/2-
t Assembly device (nut) -MP5-401/3-
t Assembly device (bearing) -MP5-402-
t Pipe -T10263/6-
Removing:

vehicle sides).
113


Vehicles with ABS

Release screw -1-.
-V.A.G 1359/2-
adapter.
outside
114
the axle.
inside

body.
Note

the axle.

the axle.
Position assembly devices, as shown, and pull

the rubber-metal bearing -1- out of the axle
body -2-.
Note
115
t
t
t
heard.
Pull out rubber-metal bearing by turning the


shown in the fig.

Installing:
116
Fasten rubber-metal bearing -1- with assembly
devices and nut -2- and insert into the axle
body -3-.

117
Insert the rubber-metal bearing -1- by turning
the nut -MP 5-401/3- up to the stop in the axle
body -2-.
bearing.
-G052 150 A2-.
outside
for the axle.


inside

vehicle side.
Note

Vehicles with ABS
118

regulator Chapter.


Note

Chapter.
119


Attach the wheels.
test drive.
Caution

Tightening torque:
t Use new screws!

t Assembly device (nut) -T10254/4-
t Assembly device (screw) -T10254/5-
t Pipe -T10263/6-
t Hydraulic cylinder -VAS 6178-
t Foot pump -VAS 6179-
Removing:
120

vehicle sides).


Vehicles with ABS
121
Release screw -1-.
-V.A.G 1359/2-
adapter.
outside
the axle.
inside
122
body.
Note

the axle.

the axle.
Connect hydraulic line -1- of hydraulic pump

-VAS 6179- with quick coupling to hydraulic
cylinder -VAS 6178-.
Connect compressed air supply -2- with quick
coupling to hydraulic pump -VAS 6179-.

Note
123
t
t
t
heard.

activated.
Pull the rubber-metal bearing -1- out of the
axle body -2-.

124

shown in the fig.

Installing:
125

2- Axle body


126
activated.
Insert the rubber-metal bearing -1- up to the
stop into the axle body -2-.

bearing.


-G052 150 A2-.
outside
for the axle.
127


inside

vehicle side.
Note

Vehicles with ABS
128
regulator Chapter.


Note

Chapter.
129


Attach the wheels.
test drive.
Caution

Tightening torque:
t Use new screws!
Removing and installing shock absorber/spring

Note
t The coil spring does not have to be removed in order to remove the shock absorber.
t The shock absorber does not have to be removed in order to remove the coil spring.
Remove the shock absorber
130
Screw out screws -1- and -2- and take out
shock absorber.
Remove spring
Remove wheel trim cap, for light-alloy wheels
remove the cap (pull-off hook in tool kit).

Disconnect the plug connection of the wheel
speed sensor cable.

Release screw -2-.
Lower the gearbox jack and remove the helical
spring.
Install
Note
Make sure that the top base (rubber) for the

t spring is correctly fitted when inserting it into
the support of the body.
t Pay attention to colour coding.
The bottom short circuit in coil must always
t
point to the centre of the vehicle.
The beginning of the spring -arrow- must be
positioned at the stop at the top of the base.
Disassembling and assembling shock absorber
131
1- Shock absorber
Note
The shock absorbers must not be disassembled and repaired.

2- Protective cap
3- Protective tube
4- Stop buffer
5- Top shock absorber bushing
t counterhold piston rod of shock absorber at the tip in order to slacken and tighten the hexagon nut
7- Protective cap
132
Repairing the wheel bearing
Repairing the wheel bearing, vehicles with front-wheel drive - drum brake

t Drive bushing -MP 3-427-
t Hub cap extractor -MP 5-404-
t Puller Kukko -20/2-
1- 4 Nm
2- Brake drum
t reset brake before removing the brake drum Fig.
3- Cap
t press off Fig. and Fig.
t inserting Fig.
t
t replace completely after each removal
t Remove wheel hub with wheel bearing from axle stud Fig.
t Pull wheel hub with wheel bearing onto axle stud Fig. and Fig.
133
Note
If the inner ring of the bearing remains on the axle stud after pulling off the wheel hub with wheel
t bearing, the old inner ring of the bearing must be pulled off before pressing on the new wheel hub with
wheel bearing Fig..
The inner ring of the bearing is a component part of the new wheel hub with wheel bearing and is
t
therefore not pressed on separately.
t
t replace completely after each removal
Note
Item
7- Axle stud
8- Axle body
Resetting brake
To do so, use a screwdriver to push the wedge
up through a hole in the brake drum.

Remove the brake drum Chapter.
134
Press off cap
Release cap from its position by gently tapping
the claw.
Press off cap
135
Remove the wheel bearing housing from the axle
stud
Use puller (commercially available) Kukko
-20/2-.
Remove inner ring of the bearing from axle stud

-204/1-.
Note
Do not damage the ABS wheel speed sensor

when pulling off the inner ring of the bearing.
Pull wheel hub with wheel bearing onto axle stud

Use assembly device -MP 5-403-.
Screw wheel hub with wheel bearing up to the
stop onto axle stud.

Screw on assembly device -MP 5-403- and pull
wheel hub with wheel bearing up to the stop.
136
Unscrew assembly device -MP 5-403- and
screw on new twelve-point nut and tighten.

Install brake drum Chapter.
Drive in cap
Note
t Replace cap after each removal.

Damaged caps allow moisture to penetrate.
t
Therefore absolutely use the shown tool.
Tightening torques:
Wheel hub with wheel bearing on axle stud 70 Nm + 40
Repairing the wheel bearing - disc brake

t Drive bushing -MP 3-427-
t Hub cap extractor -MP 5-404-
137
1- Brake disc, internally ventilated
3- 4 Nm
4- Brake disc
Assignment Electronic Catalogue of Original Parts
5- Cap
t press off Fig. and Fig.
t inserting Fig.
this wheel hub/wheel bearing unit is maintenance-free and has no play; it is not possible to undertake any
t
kind of adjustment or repair work on it!
t only replace completely after each removal
Note
If the inner ring of the bearing remains on the axle stud after pulling off the wheel hub with wheel
t bearing, the old inner ring of the bearing must be pulled off before pressing on the new wheel hub with
wheel bearing Fig.
The inner ring of the bearing is a component part of the new wheel hub with wheel bearing and is
t
therefore not pressed on separately.
138
8- Axle body
9- Brake caliper
t dismantling Fig.
10 - Axle stud
t Re-cutting the thread is not allowed.
Press off cap

Release cap from its position by gently tapping
the claw.
Press off cap
139
Remove brake caliper
Unscrew screws -A-, remove brake caliper and
attach e.g. with wire to body.

Note
Do not unscrew the brake hose to remove the

brake caliper.
Unscrew the fixing screw of the brake disc and
remove brake disc.

Remove the wheel bearing housing from the axle

stud
-20/2-.
Remove inner ring of the bearing from axle stud

-204/1-.
Note
Do not damage the ABS wheel speed sensor

when pulling off the inner ring of the bearing.
140
Use assembly device -MP 5-403-.
Fit the wheel hub with wheel bearing as far as
possible onto the axle stud.

Screw on assembly device -MP 5-403- and pull
wheel hub with wheel bearing up to the stop.

Screw on assembly device -MP 5-403- and
tighten wheel hub with twelve-point nut.

Install brake disc, screw in phillips head screw
and tighten.
Drive in cap
Note
t Replace cap after each removal.

Damaged caps allow moisture to penetrate.
t
Therefore absolutely use the shown tool.
Install brake caliper and tighten Allen screws.
Tightening torques:
Wheel hub with wheel bearing on axle stud 70 Nm + 40
Securing screw for brake disc 4 Nm
Screws for brake caliper 65 Nm
141
142
Repairing rear axle (vehicles with four-wheel drive)
Rear axle with four-wheel drive - Overview
Note

t Always replace the rusted screws/nuts.
1- Assembly carrier
t Summary of components Chapter
2- Final drive
t removing and installing manual gearbox; Rep. gr.39.
t repairing Manual Gearbox; Rep. gr.39
3- Cross member
4- Clamp
5- Anti-roll bar
t If necessary eliminate paint damage and carry out protection work against corrosion
6- Pressurized shock absorber
7- The wheel bearing
143
8- Trailing arm
9- Suspension arm
10 - Spacer
t only on vehicles with rough road suspension
t on vehicles without spacer, none must be subsequently fitted
11 - Stop buffer
12 - Coil spring
13 - Propshaft
t repairing Manual Gearbox; Rep. gr.39
14 - 60 Nm
15 - Support for final drive
144
Coil spring and shock absorber on vehicles with four-wheel drive - Summary of components
1- 60 Nm
2- Shock absorber bushing
3- Pressurized shock absorber
t check Chapter
4- Anti-roll bar
5- Self-locking nut 25 Nm
6- 110 Nm
7- Coupling rod
8- Trailing arm
t The thread -arrow A- for the support of the stop buffer Item is no longer applicable as of 08.99
if it is intended to install the stop buffer Item in the trailing arm before the manufacturing date 08.99,
t
the thread -arrow A- must be bored out to 10.5 mm
9- Spacer
10 - Stop buffer with threaded pin, 10 Nm
t is no longer inserted as of 08.99
t the stop buffer is delivered as a spare part Item
145
11 - Stop buffer with positioning pin
t as of 08.99
t the correct installation position is determined by the positioning pin
t the positioning pin must be removed on the underside when using vehicles produced before 08.99
t The beginning of the spring coil must lie against the leg -arrow-
t Fitting position of the coil spring Anchor
12 - Coil spring
t check colour coding
t replace axle-wise
13 - Base
14 - Thread in the frame side rail
if the thread of the weld nuts in the frame side rail is damaged, it can be repaired using Heli-Coli threaded
t
insert
t the rework of the thread for the weld nuts is permissible on maximum two screw points per vehicle side
t Observe the installation instructions of the manufacturer
15 - Thread in the cross member
if the thread of the weld nut in the cross member is damaged, it can be repaired using Heli-Coli threaded
t
insert
t Observe the installation instructions of the manufacturer
Removing and installing coil spring

t Spring tensioning device, e. g. -V.A.G 1752/1-
t Spring holder set, e.g. -V.A.G 1752/15-
The spring holder set consists of:
t Spring holder, -V.A.G 1752/1 5 L. U-. (bottom left)
t Spring holder, -V.A.G 1752/1 5 L. O-. (top left)
t Spring holder, -V.A.G 1752/1 5 R. U-. (bottom right)
t Spring holder, -V.A.G 1752/1 5 R. O-. (top right)
Note
The spring holder set -V.A.G 1752/15- was developed specially for vehicles with four-wheel drive. This
t
enables to securely remove and install the coil springs.
Extremely high forces are produced when tensioning the coil springs. Thus pay particular attention to the
t
following safety instructions.
WARNING
t Ensure that the spring holders are positioned as close as possible to the spring coils.
t During the tensioning operation, ensure that the spring holder is correctly located at the spring coils.
t Do not use impact screwdriver!
Remove left coil spring
146
Mount the spring holder, e.g. -V.A.G 1752/1 5
L. U-, on the spring tensioning device, e.g.
-V.A.G 1752/1-.
Position the spring holder, e.g. -V.A.G 1752/1 5
L. O-, onto the highest spring coil within reach.
Insert spring tensioning device, e.g. -V.A.G
1752/1-.
Note
Do not use any impact screwdriver or anything

similar when tensioning the coil spring.
147
Turn the spindle of the spring tensioning device
clockwise until the claws -arrows- of the spring
tensioning device and the spring holder engage.
Insert the screw -1- from below onto the top
spring holder, screw on hexagon nut and
tighten.
Turn the spindle of the spring tensioning device
until the coil spring is slightly tensioned.

- Check if the spring holders are correctly
positioned at the spring coils, if necessary correct
position
Note
Make sure to end the tensioning operation once

the spring coils touch each other
Tension coil spring sufficiently until it can be
removed.
Take the coil spring with the spring tensioning
device out of the vehicle.

Take the coil spring out of the spring
tensioning device.
1 - Spring holder, e.g. -V.A.G 1752/1-.
2 - Spring holder, e.g. -V.A.G 1752/1 5 L. O-.
3 - Spring holder, e.g. -V.A.G 1752/1 5 L. U-.
Install left coil spring
The beginning of the spring coil must be

positioned in the spring holder as shown on the
spring holder -arrow-.
1- Beginning of spring coils
Insert the coil spring into the spring tensioning
device, e.g. -V.A.G 1752/1-, with the spring
holders, e.g. -V.A.G 1752/1 5 L. U- and -V.A.G
1752/1 5 L. O- position.
- Check if the spring holders are correctly
positioned at the spring coils, if necessary correct
position.
Note
Do not use any impact screwdriver or anything

t similar when tensioning or detensioning the
coil spring.
Make sure to end the tensioning operation once
t
the spring coils touch each other.
Tension the coil spring sufficiently until it can
be installed in the vehicle.
148
Check which version of the stop buffer is
mounted on the trailing arm.

-I- - Stop buffer without stop for the coil spring
-arrow-
-Il- - Stop buffer with stop for the coil spring
-arrow-
Insert the coil spring with the spring tensioning
device into the vehicle according to the fitting
position.
Fitting position of the left coil spring
Vehicles without stop on the stop buffer:

The beginning of the spring coil -3- must be at
the 9.00 o'clock (9:00) position.
-1- Coil spring
-2- Stop buffer without stop for the coil spring
-F- direction of travel
Note
The theoretical line between 12.00 o'clock

(12:00) and 6.00 o'clock (6:00) faces parallel to
t
the longitudinal vehicle axis in direction of
travel.
The 9.00 o'clock (9:00) position is the same for
t
the left and right coil spring.
Never apply a mirror-image procedure for
t
installing the right coil spring.
Vehicles with stop on the stop buffer:
The beginning of the spring coil -3- must be
positioned at the stop -arrow-.
-1- Coil spring
-2- Stop buffer with stop for the coil spring
-F- direction of travel
Note
The fitting position is the same for the left and

t
right coil spring.
Never apply a mirror-image procedure for
t
installing the right coil spring.
Release the tension of the coil spring by turning
the spindle of the spring tensioning device anti-
clockwise.
- Check the correct fitting position of the coil
spring while carrying out the detentioning
procedure.
149
Unscrew the hexagon nut -1- and remove the
screw with the spring holder.

Take the coil spring out of the spring
tensioning device.
Removing and installing right coil spring
The removal and installation procedure of the
right coil spring is carried out in the same way as
for the left coil spring Chapter.
Instead of the special tools
Spring holder, e.g. -V.A.G 1752/1 5 L. U-.
t
(bottom left)
Spring holder, e.g. -V.A.G 1752/1 5 L. O-. (top
t
left)
the
Spring holder, e.g. -V.A.G 1752/1 5 R. U-.
t
(bottom right)
Spring holder, e.g. -V.A.G 1752/1 5 R. O-.
t
(bottom right) must be used.
Fitting position of the right coil spring
The fitting position of the right coil spring is
identical to the fitting position of the left coil
spring Anchor.
Removing and installing shock absorber

t Gearbox jack, e.g. -V.A.G 1383 A-
t Adapter, e.g. -V.A.G 1359/2-
Removing
Raise vehicle.
Remove wheel.
Remove coil spring Chapter.
Unclip wheel speed sensor cable from holder.
If necessary, partially slacken the wheel house
trim panel.
150
Unscrew top screw of shock absorber -arrow-.
Slowly lower trailing arm with gearbox jack
and adapter, e.g. -V.A.G 1383 A- with -V.A.G
1359/2-.
Unscrew bottom screw of shock absorber
-arrow-.
Remove shock absorber.
Install
If necessary, unbolt the coupling rod from the
anti-roll bar -arrow-.

In doing so, this facilitates the positioning of the
bottom screw for the shock absorber.
Tightening torques:
Shock absorber to body 60 Nm
t Use new screws!
Shock absorber at trailing arm 110
Therefore the vehicle must be positioned on its wheels with the weight load of a person seated on Nm
t
the rear seat.
151
Anti-roll bar to coupling rod 25 Nm
t Use new screws!
Wheel bolts 120
Nm
Trailing arm and suspension arm - Summary of components
Note
t Never load the wheel bearing if the drive shaft was removed!
If the vehicle should be lowered onto its wheels and moved, the outer joint of a drive shaft must be
t
temporarily inserted.
Welding and straightening work is not allowed on the bearing and wheel control components of the
t
wheel suspension.
t Self-locking nuts must always be replaced.
1- 39 Nm
152
t initially tighten crosswise to 10 Nm, then tighten crosswise to the recommended tightening torque
2- Shim
3- Assembly carrier
4- Drive shaft with inner CV joint
t repairing Chapter
5- 70 Nm + 90
t M12 x 1.5 x 80
6- Screw
t M12 x 1.5 x 75
7- Top suspension arm
t different versions, assignment Electronic Catalogue of Original Parts
8- Guide joint
9- Collar screw, 80 Nm
10 - Brake carrier with brake caliper
t repairing Chapter
t Removing and installing brake pads Chapter
11 - 10 Nm
t tighten Chapter
13 - 4 Nm
14 - Brake disc
15 - Brake disc, internally ventilated
t The pulse rotor is welded with the wheel hub
17 - Circlip
t pay attention to correct position
18 - Wheel bearing
t replace, is damaged when pressing out
t The spare part only as a set wheel bearing with mounting parts (- Pos. 12 and - Pos. 17)
19 - Cover plate
20 - Self-locking nut, 70 Nm + 90
21 - Bottom suspension arm
22 - Guide joint
153
23 - 90 Nm
t for trailing arm
25 - Trailing arm
t The thread -arrow A- for the support of the stop buffer - Pos. 29 is no longer applicable as of 08.99
if it is intended to install the stop buffer - Pos. 30 in the trailing arm before the manufacturing date 08.99,
t
the thread -arrow A- must be bored out to 10.5 mm
26 - 75 Nm
t the track can be corrected by moving the mounting bracket
28 - Spacer
29 - Stop buffer with threaded pin, 10 Nm
t is no longer inserted as of 08.99
t the stop buffer is delivered as a spare part - Pos. 30
30 - Stop buffer with positioning pin
t as of 08.99
t the correct installation position is determined by the positioning pin
t the positioning pin must be removed on the underside when using vehicles produced before 08.99
t The beginning of the spring coil must lie against the leg -arrow-
t Fitting position of the coil spring Chapter and Chapter
31 - Wheel speed sensor
t insert with solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
32 - 8 Nm
33 - Flange shaft of the rear axle gearbox
Pressing out and pressing in

t Gearbox jack with adapter, e.g. -V.A.G 1383 A- with -V. A. G 1359/2-
t Foot pump with high-pressure hose, e.g. -V.A.G 1389 A/1- (Paschke)
t Hydraulic removal and installation device for wheel bearing, e.g. -V.A.G 1459 B- (Paschke)
with the following individual tools:
t Hollow piston cylinder, e.g. -HKZ-15-, with pressure plate, e.g. -E-0-204T-
t Tie bolt, e.g. E-0-217 + 218
t Special nut, e.g. -E-8-214-
t Pressure plate, e.g. -E-5-
t Centering with clamp, e.g. -E-76-2-
t Supplementary kit, e.g. -V.A.G 1459 B/2-
with the following individual tools:
154
t Pressure bushing, e.g. -E-44-
t Bell, e.g. -E-40-
t Pressure plate, e.g. -E-6-1-
t Pressure plate, e.g. -E-13-1-
t Thrust washer, e.g. -E-39- (-VAS 5146-)
t Thrust plate -MP 3-467-
t Washer -MP 6-416-
t Extractor -Kukko 18-0-
Raise vehicle.
Remove wheel.
Removing drive shaft Chapter
Unscrew fixing screws -1- from brake carrier
and remove brake carrier with brake caliper.

Note
Top fixing screw of the brake carrier covered.

Tie brake caliper to the body. The brake line
must not be exposed to tension.

Screw out the Phillips head screws of the brake
disc and remove brake disc.

Remove the ABS wheel speed sensor from the
trailing arm housing Chapter.

Press out the wheel hub
Insert the thrust washer -1-.

Position the thrust washer -1- in such a way that it
rests fully on the screw heads -2-.
1 - Thrust washer, e.g. -E-39- (-VAS 5146-)
155
Mount centering with clamp, e.g. -E-76-2-.
Hollow piston cylinder, e.g. -HKZ-15-, with
1-
pressure plate, e.g. -E-0-204T- hydraulic
2- Tie bolt, e.g. -E-0-217-
3 - Centering with clamp, e.g. -E-76-2-
High-pressure hose with quick coupling,
4 - component part of the foot pump, e.g. -V.A.G
1389 A/1-
Mount hollow piston cylinder -1- with tie bolt
-2-, bell -5- and special nut -4-.

1-
pressure plate, e.g. -E-0-204T-
2- Tie bolt, e.g. -E-0-217-
3 - Pressure plate, e.g. -E-39- (-VAS 5146-)
4- Special nut, e.g. -E-8-214-
5- Bell, e.g. -E-40-
1389 A/1-
Build up a pressure by pumping with the foot
pump.
Check if all the tools are correctly centred, if
necessary correct position.

Note
Place gearbox jack with adapter, e.g. -V.A.G

1383/A- with -V.A.G 1359/2- underneath (risk of
accident due to falling parts while the wheel hub
is being pressed out).
Press the wheel hub out of the wheel bearing
by pumping.
Press out the wheel bearing
156
Remove circlip -1-.
Position the pressure plate -3- onto the reverse
side of the wheel bearing.

Mount hollow piston cylinder -1- with tie bolt
-2- and special nut -4-.

1-
2- Tie bolt, e.g. -E-0-217-
3- Pressure plate, e.g. -E-5-
5- Bell, e.g. -E-44-
1389 A/1-
pump.

Press the wheel bearing out of the wheel
bearing housing of the trailing arm by
pumping.
Pull the inner ring of the bearing off the wheel
hub.
Insert washer -MP 6-416- as shown.
Screw the extractor -Kukko 18-0- into the
washer -MP 6-416-.

Position thrust plate -MP 3-467- onto wheel
hub and pull off the inner ring of the bearing by
turning the threaded spindle.
Press in the wheel bearing
Position the wheel bearing at the wheel-bearing
housing.
157
side of the wheel bearing housing.

Position hollow piston cylinder -1- with tie bolt
-5-, thrust piece -2- and special nut -4-.

1-
2 - Pressure plate, e.g. -E-5-13-1-
3- Pressure plate, e.g. -E-6-1-
5- Tie bolt, e.g. -E-0-217-
1389 A/1-
pump.

Press the wheel bearing into the wheel bearing
housing of the trailing arm by pumping.

Note
t Replace circlip after each disassembly.

When inserting the circlip, pay attention to the
t
correct position of it.
Insert the new circlip -1-.

Pressing in the wheel hub
Position the wheel hub at the wheel bearing.
158
Mount centering with clamp, e.g. -E-76-2-.
1-
2- Tie bolt, e.g. -E-0-217-
3 - Centering with clamp, e.g. -E-76-2-
1389 A/1-
side of the wheel bearing housing.

Note
The shoulder -arrow- of the pressure plate -4-

must point to the special nut -3-.
Position hollow piston cylinder -1- with tie bolt
-2- and special nut -3-.

1-
2- Tie bolt, e.g. -E-0-217-
4- Pressure plate, e.g. -E-5-
1389 A/1-
pump.

Then press in the wheel hub by pumping with
the foot pump.

Install ABS speed sensor Chapter.
Install brake disc.
Install brake carrier with brake caliper.
Install drive shaft Chapter.
Tightening torques:
Screw for ABS wheel speed sensor 8 Nm
Screw for brake disc 4 Nm
Brake carrier with brake caliper to trailing arm 80 Nm
Tighten drive shaft to flange shaft M8, diagonally across in 2 steps (I and II) I II
t Use new screws! 10 Nm 39 Nm
Wheel bolt 120 Nm
Nut to wheel hub 50 Nm + 60
159
t Always use new nut!
Tightening process Chapter.
Removing and installing rubber-metal bearing for trailing arm

t Assembly device -T10030-
Remove trailing arm
Raise vehicle.
Remove wheel.
Remove coil spring -1- Chapter.

Unbolt the bracket for brake line -2- from the
trailing arm.
Unclip the brake line from the holder.
Mark the fitting position of the mounting
bracket on the body -arrows-.

Unscrew mounting bracket from body.
160
Mark the fitting position of the mounting
bracket -3- to the trailing arm -1-, e.g. with a
felt-tip pen.
See arrows and dot-dash line.
Unscrew screw -2- and remove mounting
bracket -3- from trailing arm.

Remove rubber-metal bearing from trailing arm.

Pull out the rubber-metal bearing by turning
the spindle.
-A- Ring spanner
Insert rubber-metal bearing

Insert the rubber-metal bearing by turning the
spindle.
Install trailing arm
The installation is carried out in the reverse order
Chapter.
If the fitting position of the mounting bracket to
the trailing arm was not marked, the fitting
position must be determined Chapter.
Removing and installing guide joint
161
WARNING
If the top and bottom guide joint must be replaced, first of all remove the coil spring.
Remove guide joint
Raise vehicle.
Remove wheel.
Unscrew bottom suspension arm from trailing
arm -arrow-.
Screw the wheel screw into the brake disc up to
the stop.
Fit the socket with two extensions onto the
wheel screw.
Press the extension slightly towards the top
-arrow- and release screw -2-.

Do not slacken the screw for the top
1-
suspension arm!
3- Trailing arm
4 - Do not remove bottom suspension arm!
Press the bottom suspension arm downwards
only as far as necessary so that the assembly
device can be mounted.
162
Position the special tool as shown.
Pull out the guide joint by turning the spindle.
Install bottom guide joint
Before positioning, mark the pressure piece
-T10030/1A- along the entire circumference.

Distance: 3 mm
The marking must be to the open side.
Note
The marking is needed for positioning the guide

joint in the trailing arm.

Press in the guide joint -1- by turning the
spindle until the marking on the pressure piece
-T10030/1 A- reaches the support on the

trailing arm.
Slacken special tools, do not remove.
Check whether the guide joint is centred in the
support of the trailing arm.

If this is not the case, correct the fitting position
of the guide joint accordingly.

Install bottom suspension arm Chapter.
Attach the wheel.
Lower the vehicle.
Remove top guide joint
WARNING
If the top and bottom guide joint must be

replaced, first of all remove the coil spring.
Raise vehicle.
Remove wheel.
163
Unscrew screws -A-, remove brake caliper and
tie up with wire or anything similar.

Note
Do not unscrew the brake hose to remove the

brake caliper.
Screw out the screw for the brake disc and
remove the brake disc.
Unscrew screw -1- from the assembly carrier.

Unscrew nut -2- for top suspension arm.
Unscrew the nut of screw -1-.

Screw the wheel screw into the wheel hub up
to the stop.
wheel screw.
164
Press the extension downwards only as far as
necessary -arrow 1- so that the top suspension
arm -arrow 2- can be removed upwards.
Note
If the extension is pressed downwards too much,

the drive shaft can get damaged.
Pull the screw and the top suspension arm out
of the assembly carrier.

Pull out the guide joint by turning the spindle.
Install top guide joint.
Before positioning, mark the pressure piece
-T10030/1A- along the entire circumference.

Distance: 3 mm
The marking must be to the open side.
Note
The marking is needed for positioning the guide

joint in the trailing arm.
165
Press in the guide joint -1- by turning the
spindle until the marking on the pressure piece
-T10030/1 A- reaches the support on the

trailing arm.
Slacken special tools, do not remove.
Check whether the guide joint is centred in the
support of the trailing arm.

If this is not the case, correct the fitting position
of the guide joint accordingly.

Install top suspension arm Chapter.
Attach the wheel.
Lower the vehicle.
Removing and installing trailing arm

Removing
Raise vehicle.
Remove wheel.
Remove coil spring -1- Chapter.

Unbolt the bracket for brake line -2- from the
trailing arm.
If necessary, unclip the brake line from the
holder.
Lower the vehicle.
Remove rear centre console Body
Work; Rep. gr.70.

166
Release the adjusting nut -1- so far until the
hand-brake cable can be unhooked from the
compensating clamp -2-.
Raise vehicle.
Lift off the clip -1- with a screwdriver and pull
down to remove.
Press the brake lever -2- in the -direction of the
arrow- and unhook the hand-brake cable -3-.
Remove the rubber grommet -arrow A- from
the trailing arm.

Unhook the hand-brake cable out of the bracket
-arrow- and pull it out of the trailing arm in
-direction of arrow-.
Remove drive shaft on the side Chapter.
167
Unclip cable for ABS wheel speed sensor from
bracket -arrows-.
trailing arm housing.
Unscrew fixing screws -1- from brake carrier
and remove brake carrier with brake caliper.

Note
Top fixing screw of the brake carrier covered.

Tie brake caliper to the body. The brake line
must not be exposed to tension.

Screw out the Phillips head screws of the brake
disc and remove brake disc.
168
Release the screws -1- and -2- for the
suspension arm.
4- Bottom suspension arm
5- Trailing arm

-V.A.G 1383A- with -V.A.G 1359/2-, under the
trailing arm.
Unscrew screw -1- of shock absorber.
169
Separate the brake lines at the pipe connection
-1-.
Close off immediately brake lines.
Mark the installed position of the bracket on
the body.
Unscrew mounting bracket from body
-arrows-.
Note
If it is intended to replace the trailing arm, the

t
mounting bracket must be modified.
The installation position of the mounting
t bracket must then be adjusted as described on
page Anchor.
Determine the fitting position of the bracket to
the trailing arm
Dimension -a- is 53.5 + 2 mm

1- Bearing bracket
2- Trailing arm
Install
Setting the hand-brake Chapter.
After installing, check the track and the camber
on the wheel alignment tester, adjust if necessary
Chapter.
Tightening torques:
Mounting bracket to trailing arm 90 Nm
Bracket to body 75 Nm
Suspension arm to trailing arm 70 Nm +
t Use new screws and nuts! 90
Shock absorber at trailing arm 110 Nm
Therefore the vehicle must be positioned on its wheels with the weight load of a person
t
seated on the rear seat.
Tighten drive shaft to flange shaft M8 diagonally across in 2 steps (I and II) I II
t Use new screws! 10 39
Nm Nm
Pipe connection of brake line 14 Nm
Wheel bolt 120 Nm
Nut to wheel hub 50 Nm +
t Always use new nut! 60
Tightening process Chapter.
170
Removing and installing suspension arm
WARNING
If the top and bottom suspension arm must be replaced, first of all remove the coil spring.
Remove bottom suspension arm
Raise vehicle.
Remove wheel.
Unscrew bottom suspension arm from trailing
arm -arrow-.
the stop.
wheel screw.

Do not slacken the screw for the top
1-
suspension arm!
3- Trailing arm
4- Bottom suspension arm
171
Screw out the screw -2- on the assembly
carrier.
Remove the bottom suspension arm -4- from
the assembly carrier.

Install bottom suspension arm
The screws for the bottom suspension arm must
only be tightened when the vehicle is standing on
its wheels!
Chapter.
Tightening torques:
Suspension arm to trailing arm 70 Nm + 90
Suspension arm to assembly carrier 70 Nm + 90
Remove top suspension arm

WARNING
If the top and bottom suspension arm must be replaced, first of all remove the coil spring.
Raise vehicle.
Remove wheel.
Unscrew screw -1- from the assembly carrier.

Unscrew nut -2- for top suspension arm.
172
Unscrew the nut of screw -1-.
the stop.
wheel screw.
Press the extension downwards only as far as

necessary -arrow 1- so that the top suspension
arm -arrow 2- can be removed upwards.
Note
If the extension is pressed downwards too much,

the drive shaft can get damaged.
Pull the screw and the top suspension arm out

Install top suspension arm
The screws for the top suspension arm must only
be tightened when the vehicle is standing on its
wheels!
Chapter.
Tightening torques:
Suspension arm to trailing arm 70 Nm + 90
Suspension arm to assembly carrier 70 Nm + 90
Assembly carrier to body 110 Nm + 90
t Use new screw!
173
Summary of components - Assembly carrier with final drive
1- 60 Nm
2- Cross member
3- Rubber-metal bearing for final drive
t Observe fitting position: kidney-shaped openings or arrow must point vertically upwards or downwards
4- Rubber-metal bearings for assembly carrier
t are supplied as spare parts in a sealed plastic bag
t do not use any rubber-metal bearings which have been stored openly
t Observe fitting position: ribbed side must point upwards
5- 110 Nm + 90
6- Assembly carrier
7- Support for final drive
8- 40 Nm + 45
t M10 x 40
9- 40 Nm + 45
174
t M10 x 55
10 - Rear final drive
12 - Anti-roll bar
13 - 20 Nm
t mate both screws and initially tighten to 5 Nm, subsequently tighten
14 - Clamp
15 - Coupling rod
Removing and installing assembly carrier with final drive

t Support, e.g. -T10031-
Removing
Raise vehicle.
Remove wheels.
Remove coil springs Chapter.
Open double pipe clamp downstream of catalytic converter and remove rear exhaust pipe.
Remove heat shield from rear silencer.
Note
After unscrewing the propshaft, absolutely mark the fitting position. In the event of an offset installation,
the imbalance is too great.
Unscrew the propshaft from the final drive.

1 - Propshaft with mass damper
2- Flange for propshaft
Do not turn the propshaft or the flange for the
propshaft.
Mark the fitting position of the propshaft and
the flange for the propshaft -Pfeile-.

Lower the vehicle.
Remove the centre console Body
Work; Rep. gr.68.

175
Release the adjusting nut -1- so far until the
hand-brake cable can be unhooked from the
compensating clamp -2-.
Raise vehicle.
Lift off the clip -1- with a screwdriver and pull
down to remove.
Press the brake lever -2- in the -direction of the
arrow- and unhook the hand-brake cable -3-.
Remove the rubber grommet -arrow A- from
the trailing arm.

Note
If it is intended to only lower the assembly

carrier, e.g. when replacing the rubber-metal
bearings, the hand-brake cables must not be
pulled out of the trailing arm.
Unhook the hand-brake cable out of the bracket
-arrow- and pull it out of the trailing arm in
-direction of arrow-.
176
Unclip cable for ABS wheel speed sensor from
holder -arrows-.
trailing arm housing.
Separate the brake lines at the pipe connection
-1-.
Close off immediately brake lines.
Unscrew bottom screw of shock absorber
-arrow-
177
-V.A.G 1383 A- with -T10031-, under the
assembly carrier -1-.
Guide the bolts -1- into the holes of the
assembly carrier -arrows-.

Disconnect vacuum line and electrical line.
Mark the installed position of the bracket on
the body.
Unscrew mounting bracket from body
-arrows-.
178
Release screws for assembly carrier -arrows-.
Slowly lower rear axle with gearbox jack and
adapter, e.g. -V.A.G 1383 A- with -T10031-.

Install
Tighten the screws for the assembly carrier and
the mounting brackets on the marked fitting
position.
Chapter.
Tightening torques:
t Use new screws!
Assembly carrier to body 110Nm +
t Use new screws! 90
Propshaft at final drive 60 Nm
t
Wheel bolt 120 Nm
Removing and installing rubber-metal bearing for assembly carrier

Removing
Raise vehicle.
Remove wheels.
Remove assembly carrier with final drive Chapter.
179
Position the special tools.
the spindle.
Install
Note
The rubber-metal bearings are supplied as spare

t
parts in a sealed plastic bag.
Do not use any rubber-metal bearings which
t
have been stored openly!
Mount the rubber-metal bearing with the
special tools.
For the correct installation position of the rubber-
metal bearing in the assembly carrier, the ribbed
side must point in the -direction of the arrow B-.
The collar of the special tool -T10030/4--arrow
A- points to the rubber-metal bearing -1-.
If necessary, coat the rubber-metal bearing with
water for inserting.
Position the rubber-metal bearing and the
special tools on the assembly carrier.

spindle.
-A- Ring spanner
The ribbed side of the rubber-metal bearing
must point upwards -arrow-.

Note
For removing and installing the front rubber-

metal bearings on the assembly carrier, the
spindle must be inserted from below.
Install assembly carrier with final drive
Chapter.
Chapter.
Tightening torques:
180
t Use new screws!
t
Wheel bolt 120 Nm
Removing and installing rubber-metal bearing for final drive

Raise vehicle.
Remove wheels.
Remove assembly carrier with final drive
Chapter.
To do so, use gearbox jack with adapter, e.g.
-V.A.G 1383 A- with -T10031-.

Support final drive -1-.
Note
For reason of clarity the surrounding was not

shown in the fig. S42-0100.
181
If necessary, remove the anti-roll bar -3-.
Release screws -1-.
Remove the clamp -2- and the anti-roll bar with
bearing and coupling rod.

4- Assembly carrier
Note
For reason of clarity the surrounding was not

shown in the fig. S42-0101.
Remove plug connection -1- from holder.

Unscrew splined nut -arrows-.
Remove suspension arm -2- from final drive.
Slacken the internal serration screw -1- of the
support for final drive -2- on both sides.

Move the final drive by approx. 15 to 20 mm
-arrow-.
182
the spindle.
Install
The kidney-shaped openings -A- or the arrow on

the rubber-metal bearing -1- must point vertically
upwards or downwards.
Permissible variation of the vertical line 2.
If necessary, coat the rubber-metal bearing with
water for inserting.

spindle.
Install assembly carrier with final drive
Chapter.
183
If removed, install the anti-roll bar -3- with the
coupling rod, a 2nd mechanic is required.

Position the clamp -2- on the bearing, mate
both screws -1- and initially tighten to 5 Nm.

Tighten both screws to the specified tightening
torque.
4- Assembly carrier
Chapter.
Tightening torques:
t Use new screws!
Anti-roll bar to assembly carrier 20 Nm
t
Cross member for final drive to assembly carrier 60 Nm
Support for final drive to assembly carrier 60 Nm
Wheel bolt 120 Nm
184
Repairing drive shaft
Removing and installing a drive shaft

Removing
Note
The wheel bearing must not be loaded when the twelve-point nut is loose. At full load the wheel bearing
t
is initially damaged through the vehicle's own weight, thus shortening the life of the wheel bearing.
t
Assignment Electronic Catalogue of Original Parts
Left and right drive shaft
Thus the wheel must still touch the ground.
Raise the vehicle to working height.
Unscrew the drive shaft -1- from the flange
shaft of the final drive -2-.

Left drive shaft
Press the exhaust system -1- to the side using
an assembly lever.
Remove inner joint of drive shaft -2- from final
drive.
The further work procedure is now valid again for
both sides.
Note

185
Push out the drive shaft.
A- Wheel bolts
Remove the drive shaft.
Install
Remove possible paint and/or corrosion residue
from the thread/the serration of the outer joint
Before inserting the drive shaft, moisten the
following parts with oil.

t Serration of the outer joint
t Thread of the outer joint
t Serration of the wheel hub
The contact surface and the thread of the new
t
twelve-point nut
Insert drive shaft.

Insert the outer joint into the wheel hub by
screwing on the twelve-point nut until the outer
joint rests in the wheel bearing.
Position the inner joint of the drive shaft onto
the flange shaft of the final drive and tighten
the screws to 39 Nm.

wheel bearing.
mechanic required) or pull on the handbrake.

release by one turn.

Tightening torque:
50 Nm + 60
Note
186
Repairing drive shaft with CV joint

t Circlip pliers, e.g. -VW 161 A-
t Tensioning pliers, e.g. -V.A.G 1682-
Note

t Spread the grease mass evenly in the joint boot.
187
1- Outer CV joint
t removing Fig.
t grease Chapter
t check Chapter
2- Circlip
t replace
3- Thrust ring
4- Disc spring
t replace
t tension with tensioning pliers, e.g. -V.A.G 1682- Fig.
6- Joint boot
t replace
t tensioning Fig.
8- Drive shaft (solid shaft)
9- 39 Nm
t M8 x 48
10 - Shim
188
t replace
t tensioning Fig.
12 - Joint boot for inner CV joint
t remove with a drift
13 - Disc spring
14 - Inner CV joint
t pressing off Fig.
t pressing on Fig.
t grease Anchor
t check Chapter
15 - Gasket
t replace
t Remove the protective foil and stick the gasket into the inner joint
16 - Circlip
t replace
t remove and install with sprung pliers, e.g. -VW161 A-

Note
The CV joints are filled with grease for operating at normal temperatures e.g. -N 052 738.00-.
Grease of which in:
Outer joint Total amount Joint Joint boot
mm [g] [g] [g]
90 90 40 40
Inner joint
100 120 50 70
189
Removing outer CV joint
Drive off the drive shaft with a strong blow of
a plastic hammer.
Pressing out the inner CV joint

Note
t First of all drive off joint boot with a drift.

t Support ball hub.
Fitting position of the disc spring at inner joint

1- Disc spring
190
Fitting position of the disc spring and thrust ring
on the outer joint
1- Disc spring
2- Thrust ring
Pressing in the inner CV joint

Note

(serration) must point towards the bearing collar
of the drive shaft.
Press the joint up to the stop.
Insert the circlip.
Note
In view of the hard material (as opposed to

rubber) of the joint boot, which requires the use
t of a stainless steel open warm-type clamp, the
latter can only be correctly tightened with
tensioning pliers, e.g. -V.A.G 1682-.
t Tightening torque: 20 Nm
t Use a torque wrench.
Make sure the thread of spindle -A- of the
t tensioning pliers is smooth. If necessary grease
with grease, e.g. molykote -MOS2-.
If it is not smooth, e.g. if the thread is dirty, the
t necessary clamping force of the open warm-
type clamp is not reached at the given torque.
191
type clamp on the outer
joint (at the large
diameter)
Position the tensioning
pliers, e.g. -V.A.G
1682-, as shown in the
fig. Make sure the
cutting edges of the

pliers are positioned in
the corners -arrows B-
of the open warm-type
clamp.
type clamp by turning
the spindle with a
torque wrench (do not
tilt the pliers during this
process).
Spindle of tensioning
A-
pliers
Cutting edges of
B-
tensioning pliers
Tighten the open warm-type clamp on the outer

joint (small diameter)

corners -arrows B- of the open warm-type
clamp.
A- Spindle of tensioning pliers
B - Cutting edges of tensioning pliers
C- Torque wrench
192
Tighten the open warm-type clamp on the inner
joint

corners -arrows B- of the open warm-type
clamp.
A- Spindle of tensioning pliers
B - Cutting edges of tensioning pliers
C- Torque wrench
193
Wheels, tyres. axle align
Vehicle alignment
General points
The vehicle must only be aligned using an alignment gauge released by the manufacturer!
It is recommended to align the front and rear axles during each vehicle alignment procedure.
Otherwise correct vehicle driving behaviour cannot be guaranteed!
Note
Only perform a vehicle alignment after the first 1000 to 2000 km to allow the helical springs to fully
t
settle.
t During adjustment work try to approximate the nominal values.
For vehicles equipped with ESP, the basic setting must be carried out after the axial measurement,
t
function 04, group 060 Chapter.
If the fitting position of the rear axle and hence the running direction of the vehicle are not considered this
could result in a skewed steering wheel.
Removing and installing steering wheel Body Work; Rep. gr.69.
It is necessary to perform a vehicle alignment in the event of:
t incorrect driving behaviour;
t damage caused by accident and if parts have been replaced;
t axle parts have been removed;
t there is unilateral tyre wear.
Front axle part replaced Chassis alignment required Rear axle part replaced Chassis alignment required
yes no yes no
track control arm X Shock absorber X
Wheel-bearing housing X Coil spring X
Track rod/track-rod ends X Complete rear axle X
1)
Steering gear X Assembly carrier X
1)
Assembly carrier Bottom suspension arm
X X
Top suspension arm 1)
Suspension strut X Trailing arm 1) X
1)
Only on vehicles with four-wheel drive
194
Test conditions
l Determine the chassis version according to the vehicle data sticker Chapter.
Check the wheel suspensions, wheel bearing, steering and steering linkage for impermissible play and
l
damage, if necessary repair.
l Check tyre inflation pressure, if necessary correct BookletOctavia or fuel-tank cap sticker.
Check the tyre tread depth. The difference between the left and right tyres on an axle must not exceed 2
l
mm.
l The unladen weight of the vehicle must correspond with the vehicle documents.
Unladen weight: Weight of the vehicle with full fuel tank and full water reservoir for windscreen
wiper/washer and headlamp cleaning system, spare wheel, tool kit, jack and without driver. The spare
wheel, tool kit and jack must be located in the position prescribed by the vehicle manufacturer.
Vehicle must be aligned, with the springs having been repeatedly deflected and having returned to their
l
original position.
l Make sure that during alignment no sliding base and no rotating plate touch the limit stop.
l The steering wheel must be in the posItion required to drive straight ahead .
Very important!
The measuring device must be positioned and adjusted in compliance with the specifications; observe the
l
manufacturer's instructions!
If necessary obtain information on your alignment gauge from the manufacturer.
In the course of time the alignment platform and alignment gauge/alignment computer may deviate from
their original adjustment/setting.
The alignment platform and alignment gauge/alignment computer must be tested and adjusted during a
maintenance operation at least once a year or following the manufacturer's instructions and if necessary be
adjusted!
Treat these precision instruments with great care.
Measurement preliminaries
The lateral runout on the rims must be balanced (compensated).

Correct toe-in adjustment is impossible if the rim run-out has not been compensated!
Comply with the instructions of the alignment gauge manufacturer.
Perform a rim runout compensation.
Lower vehicle and deflect the springs.
Insert brake pedal arrester, e.g. -V.A.G
1238/B-.
Overview of the work sequence for vehicle
alignment
The following sequence of work steps must
always be respected!
Determine what chassis has been mounted in
1 - the vehicle. This information can be found on
the vehicle data sticker Chapter.
Check camber on front axle, if necessary take
2-
the mean Chapter.
3 - Check camber on rear axle Chapter.
Checking the track on the rear axle, if
4 - necessary taking the mean/adjusting
Chapter.
Vehicles with front-wheel drive: The track of the
195
rear axle is not adjustable, only take the mean of
the track.
Vehicles with four-wheel drive: The track on the
rear axle is adjustable.
Check the track on the front axle, if necessary
5-
adjust Chapter.
The following always applies!
Always check the transversal inclination of the
vehicle before adjustment if one of the measuring
values is outside the tolerance Chapter.
196
Chassis terms
Nominal values for vehicle alignment
t Nominal values front axle Chapter

t Nominal values rear axle Chapter
Checking the transversal inclination of the vehicle
Transversal inclination of the vehicle straight-ahead position

It is possible the vehicle is skew if the measured values lie outside the tolerance of the nominal values for
the front and rear axle ( Chapter).
RHD vehicles or e. g. vehicles with an automatic gearbox may be slightly skew.
This is normal and is due to the fitting locations of the assemblies and the related weight transfer.
Deflect the vehicle repeatedly and allow the springs to return to their original position.
Note
Only determine dimension a on the rear axle.

Determining dimension a for the left and
right vehicle side.

-a-left - left vehicle side
-a-right- right vehicle side
= 90
Compare dimensions -a-left and -a-right.
The deviation between -a-left and -a-right must
neither exceed nor fall short of 5.0 mm.
Correct any deviations outside the tolerance of
5.0 mm.
If the deviation is exceeded, e.g. 8,0 mm, correct
the difference on the rear axle on the relevant side
by placing weights in the boot.
Suitable weights are e.g. sand bags approx. 10
kg
Checking the camber on the front axle, if necessary take the mean
The camber cannot be adjusted, it can only be centred!

If the values lie outside the tolerance the transversal inclination must be checked and if necessary adjusted
Chapter.
It is only possible to evenly center the camber within the tolerance range by shifting the complete engine-
gearbox assembly carrier.
197
Release screws -1- and - 2-.
Move the assembly carrier until the camber is
equal on both sides.

Subsequently check the castor.
When moving the assembly carrier the castor may
change.
Tighten the assembly carrier with new screws.
Tightening torques:
Assembly carrier to body 100Nm + 90
t Screw position -1-
t Use new screws!
Assembly carrier to body 100Nm + 90
t Screw position -2-
t Use new screws!
198
Checking the camber on the rear axle
The camber cannot be adjusted.

Chapter.
If the measured values still lie outside the tolerance, check the axle body for damage and if necessary
replace.
Checking the track on the rear axle, if necessary taking the mean/adjusting
Chapter.
Vehicles with front-wheel-drive
The overall track of the rear axle is not adjustable.
It is only possible to take the mean of the individual track values equally by moving the mounting brackets.
Loosen all screws of the mounting bracket -1-.

Move the bracket of the rear axle -1- in
transverse direction.
-2- Rear axle body
Tighten screws: 30 Nm + 90.
Always use new screws!
If the measured values still lie outside the
tolerance, check the axle body for damage and if
necessary replace.
Vehicles with four-wheel drive
The overall track value of the rear axle is
adjustable.
Loosen all screws of the mounting bracket -1-.

Move the mounting bracket -1- in transverse
direction.
2- Trailing arm
Tighten screws: 75 Nm.
Always use new screws!
Check the overall track after adjusting the
single track. The overall track must correspond
with the specified nominal value Chapter.
199
Checking the track on the front axle, adjusting if necessary
Chapter.
Release counternut -1 -.
Adjust track by turning the left and/or right
track rod.
Position open-end wrench on hexagon -arrow-.
Check that the bellows have not become twisted
after turning the track rods!
Twisted bellows wear fast. Bellows replace if
damaged.
Tighten counternut -1- with 50 Nm and again
check track value.

After tightening counternut -1- the set value may
change slightly.
Make sure this value remains within the tolerance
for the nominal value. If this is not the case repeat
the track adjustment operation.
Checking the left and right steering angle
This check is only required if:

t the steering angles differ by more than 2 from the steering centre.
t at full steering angle the tyres come into contact with components on the front axle or body on one side,
t the left/right turning clearance circle differs.
The distance between the components on the
front axle and the tyres -arrow- must be the same
on both sides at maximum steering angle.
If the distance is unequal it is possible to correct
the distance by turning the left and right track
rod.
Example:
The distance between the front axle components
and the tyres is smaller on the right than on the
left.
Release the counternuts on the track rods.
Turn the track rod on the left (slightly unscrew
from track-rod end).

Turn the track rod on the right to the same
extent (screw into track-rod end).

Check overall track.
After this adjustment procedure the overall track
must correspond with the specified nominal
value!
Tighten counternuts to 50 Nm.
After tightening the counternuts the set value may
change slightly.
Make sure this value remains within the tolerance
for the nominal value. If this is not the case repeat
200
the overall track adjustment operation.
Check that the bellows have not become twisted
after turning the track rods!
Twisted bellows wear fast. Bellows replace if
damaged.
Calculation of the misalignment on the rear axle
Note
The indicated values are only given as an example.

For track values with the same preceding sign (+/+ or -/-) subtract the smaller value from the greater
value and divide by 2.

Track value Track value
on the left rear wheel on the right rear wheel
+ 15' + 5'
15' - 5' = 10'
10' : 2 = 5'
Misalignment of the rear axle = 5'

Value with a different preceding sign (+/-) are added up and the sum is divided by 2.
Track value Track value
on the left rear wheel on the right rear wheel
+ 15' + 5'
15' + 5' = 20'
20' : 2 =10'
Misalignment of the rear axle = 10'

The relevant result is the actual deviation of the running direction from the longitudinal vehicle axis.
201
Wheels and tyres
Wheel/tyre combinations Chapter
General points
For safety reasons never change tyres individually but at least in axle pairs.
Tyres with the greatest tread depth must always be fitted at the rear.
It is recommended to fit tyres of the same make, same type and tread pattern on all wheels.
When replacing the disc wheel or the tyre always replace the rubber valve.
Mount the tyre with the DOT marking pointing towards the outside of the wheel. This applies only to the
left side of the vehicle for directional tyres.
For directional tyres mount a wheel/tyre combination for the right side of the vehicle as spare wheel.
Disc wheel
Note
t Because of design variations the disc wheel and wheel trim cap may differ from the figure.
t When using anti-theft wheel bolts, the anti-theft bolt must be as close as possible to the valve.
1- Tyres
2- Wheel rims
t 6J x 14 H2, ET38
t 6J x 15 H2, ET38
202
4- Remove wheel trim cap
5- Pull-off hook
6- Wheel bolt key
t included in tool kit
7- Balancing weights
t max. 60 g allowed per rim flange
8- Retaining spring for balancing weights
9- Valve
t only use valve in accordance with spare part catalogue
Light-alloy wheel
Because of design variations the light alloy rim and wheel trim cap may differ from the figure.
1- Tyres
2- Light-alloy rim
t 6J x 15H2, ET38
t 6.5J x 15 H2, ET43
t 6.5J x 16 H2, ET42
4- Wheel bolt key
5- Pull-off shackle
t included in tool kit
6- Cap
7- Wheel trim cap
203
8- Adapter for anti-theft wheel bolt
9- Cap for anti-theft wheel bolt
10 - Anti-theft wheel bolt, 120 Nm
11 - Balancing weights
t max. 60 g allowed per rim flange
12 - Retaining spring for balancing weights
13 - Valve
t only use valve in accordance with spare part catalogue
Vehicles with tyre repair set
koda vehicles are equipped, depending upon vehicle equipment, with a spare wheel or a tyre repair set
(BREAKDOWN SET).
The tyre repair set is located in the luggage

compartment where the spare wheel is normally
situated. In addition to the compressor -1-, it also
contains a tyre inflation bottle with sealant -2-.
Tyre sealant
The tyre sealant in the bottle is perishable.
Therefore, the best before date is given on the

bottle -arrow-.
In this example the best before date 05/2003 has
expired, therefore the bottle must be replaced. If
the bottle was opened, e.g. when having a flat
tyre, it must also be replaced.
204
205
Tyre disassembly
A tyre which was filled or sealed with tyre sealant must be cleaned, e.g. with a damp cloth, after detaching it
from the wheel rim (when it is repaired).
WARNING
The tyre sealant must not come in contact with the eyes or the skin.
The tyre sealant is harmful to your health, it can cause eye irritation or allergy.
Wear safety gloves and safety goggles during work.
Detach the tyre from the wheel rim.
Clean the wheel rim e.g. with a damp cloth.
Change the damaged tyre, if necessary contact Customer Service regarding a possible tyre repair.
Assembly of new tyres
l Ensure that the wheel rim is cleaned.
Fit a new tyre valve e.g. using the tool -VAS
6459--1-.
Screw out valve core.
Inflate tyre to 0.3...0.4 MPa (3...4 bar),
whereby the bead must be heard to slip off the
rim edge.
Screw in valve core.
Correct the pressure to the required value.
Balance the wheel.
206
Disposing of tyre sealant
t Tyre sealant or residues of this should not be mixed with other wastes / fluids.
Residues of tyre sealant must be collected and stored in plastic tanks and transferred to the contract dealer
t who is responsable for waste materials. This is also valid for agents with expired best before dates.
Sealant as waste is listed in the waste catalogue under the number 08 04 10 as hazardous waste.
207
ABS, ADR, TCS, EDL, ESP
Antilock braking system (ABS) ITT Mark 20 IE
Safety precautions, basic information on fault finding and on repairing ABS and ABS/EDL ITT
Mark 20 IE
The ABS, ABS/EDL are vehicle safety systems; system knowledge is required for working on such
t
systems.
Faults are indicated by the warning light for the
-ABS K47--1- and the red warning light for the
hand brake/brake fluid level -KU/33--2-.
t
Certain faults are not detected until after a
minimum speed of 20 km/h has been exceeded
(conduct a road test).
If the ABS warning light -K47- and the warning
light for the hand brake/brake fluid level
-K14/33- do not light up and if in spite of this
t
the brake system is not fully operational, look
for the fault in the conventional brake system
Chapter and Chapter.
Notes on rectifying sudden faults Technical
Service Handbook binder Current Flow
t
Diagrams, Electrical Fault Finding and Fitting
Locations
208
Notes on repair work on ABS and ABS/EDL ITT Mark 20 IE
Before commencing work on the ABS system it is necessary to interrogate the fault memory in order to
t
check complaints and conduct specific fault finding.
t Do not separate plug connections unless the ignition is switched off.
Before commencing work on the ABS, ABS/EDL, switch off the ignition and disconnect the earth strap at
t
the battery. On models fitted with a coded radio set, pay attention to the coding; determine if necessary.
t Welding work using electric welding equipment may affect the ABS, ABS/EDL system.
t Before commencing welding work using electrical welding tool:
Disconnect the terminal from the negative pole of the battery and cover the negative pole, if necessary
remove the battery.

Connect the earth connection of the electric welding tool directly to the part to be welded. There must not
be any electrically insulated parts between the earth connection and the welding point.
Electronic control units and electrical wiring must not touch the earth connection or the welding
electrode.
t Do not drive the vehicle if the connector is unplugged from the control unit.
t Only carry out work on the hydraulic control unit within the repair measures mentioned here.
When carrying out work on the antilock brake system, ensure scrupulous cleanliness, on no account use
t
agents containing mineral oils, such as oil, greases, etc.
Thoroughly clean connection points and the surrounding area before disconnecting, but do not use any
t
aggressive cleaning agents, such as brake cleaner, petroleum, thinner or similar.
t Place removed parts on a clean surface and cover.
t After separating the control unit/hydraulic unit use the transport protection for valve domes.
Carefully cover or close opened components if the repair is not completed immediately. (Use screw plug
t
from the repair set SP no. -1 HO 698 311 A-)
t Do not use fluffy cloths.
t Remove spare parts from their wrapping immediately before fitting.
t Use only genuine wrapped parts.
t If the system is opened, avoid working with compressed air and avoid moving the vehicle.
t Ensure that no brake fluid is able to flow into the connectors.
t Observe the current regulations when handling brake fluid Chapter.
After completing work which involved opening the brake system, bleed brake system with brake filling
t
and bleeding device, e.g. -VAS 5234-, Chapter.
During the subsequent road test, ensure that at least one controlled brake application is performed (pulsing
t
must be felt on the brake pedal).
209
Required technical information
t Binder Current Flow Diagrams, Electrical Fault Finding and Fitting Locations
t Self-study programme no. 26: vehicle safety - new technical information
t Technical Service Handbook
210
Distinguishing features of the ABS ITT Mark 20 IE and the ABS/EDL ITT Mark 20 IE
General Instructions
The ABS prevents the wheels from locking during a brake application initiated by the driver.
The electronic differential lock, EDL, is a starting-off aid. A supporting torque is created for the differential
by electronically controlling the braking of the driven wheel which is slipping. The engine power is thus
available for the gripping wheel with the better adhesion. This also applies when reversing.
The brake system is split diagonally. Brake servo assistance is provided pneumatically by the vacuum brake
servo unit.
Vehicles fitted with ABS and ABS/EDL ITT Mark 20 IE do not have a mechanical brake pressure regulator.
Specifically matched software in the control unit, the electronic brake pressure distribution, EBD, regulates
the brake pressure on the rear axle.
The hydraulic pump -V64-, the hydraulic unit -N55- and the control unit -J104- form the hydraulic control
unit. A repair is only possible in the removed condition.
New control units supplied through the Parts Division are not coded. They must be coded after installation
Chapter.
ABS ITT Mark 20 IE
distinguishing features:
t Dimension -A-: 100 mm.
8 valve domes: The protective sleeves for the
t valves are visible if the control unit is separated
from the hydraulic unit Chapter.
Control unit identification. The control unit
version is shown on the display of the vehicle
system tester -V.A.G 1552-. Select function 01
t
interrogate control unit version Chapter.
ABS without CAN BUS ABS with CAN BUS
electronic catalogue of original parts
t Overview of selectable functions Chapter.
ABS/EDL ITT Mark 20 IE
211
10 valve domes: The protective sleeves for the
t valves are visible if the control unit is separated
from the hydraulic unit Chapter.
Control unit identification. The control unit
version is shown on the display of the vehicle
system tester -V.A.G 1552-. Select function 01
t interrogate control unit version Chapter.
ABS/EDL without CAN BUS ABS/EDL with
CAN BUS electronic catalogue of original
parts
Fitting position ABS or ABS/EDL ITT Mark 20 IE
Left-hand drive vehicles

1- Brake servo unit 10''
2- Hydraulic unit
25-pin control unit screwed to the hydraulic
3-
unit
Right-hand drive vehicles

1- Brake servo unit 7''/8''
2- Hydraulic unit
3-
unit
212
213
Self-diagnosis
Self-diagnosis functions
Vehicles with data BUS (CAN BUS)

As the control units are interlinked over a data BUS line, always start fault finding by interrogating the
contents of the fault memories of all the control units fitted to the vehicle.
The interrogation of the fault memory is performed with the key function 00 - Automatic test sequence.
When doing so check whether a possibly stored fault might affect the ABS system.
All vehicles
The 25-pin ABS control unit -J104- together with the hydraulic unit forms a compact unit. The unit is
located in the left of the engine compartment. The control unit is equipped with a fault memory. The
connection for self-diagnosis is located in the storage compartment on the driver's side.
Self-diagnosis relates to the electrical/electronic part of the ABS, i. e. faults are detected only over the
electrical connection to the control unit (e.g. open circuit of a wheel speed sensor).
The control unit detects faults during the operation of the vehicle and stores them in a permanent memory,
whose information is retained even if the battery voltage is disconnected.
Faults which occur sporadically (isolated) are likewise detected and stored. If this fault no longer occurs
during 50 vehicle starts and driving-off procedures, it is erased from the fault memory (fault delete counter),
with the exception of the fault Control unit defective.
After the ignition is switched on, the ABS warning light -K47- and the red warning light for the hand
brake/brake fluid level -K14/33- light up for approx. 2 seconds.
During this period a test sequence (self-check) is performed in the control unit with the following functions:
t Test of supply voltage, min. 10.0 V
t Test of control unit including valve coils.
t Check of control unit coding
t Static test of the wheel speed sensor (without speed signal)
After a start-up, should it appear that the speed signal is not O.K as of approx. 20 km/h, the ABS warning
t
light lights up again -K47-.
Systematically initiate self-diagnosis at the start of fault finding and retrieve the stored information using the
vehicle system tester -V.A.G 1552- or fault read-out scan tool -V.A.G 1551-
Note
The following description only relates to the vehicle system tester -V.A.G 1552- using the current
t
program card.
The use of the fault reader -V.A.G 1551- with integrated printer is similar. A minor deviation on the
t
display read-out is possible.
t To end the self-diagnosis or to switch to another address word select function 06 End output.
t Identify the faults displayed by referring to the fault table and subsequently carry out the fault elimination.
On vehicles with the ABS system, the functions Reading measured value block, Coding control unit,
Basic setting (only necessary for vehicles with EDL) and the Final control diagnosis are added to the
self-diagnosis.
214
Indication of faults by means of warning
lights -K47- and -K14/33-
If the ABS warning light (-K47-) -1- does not

go out after the ignition is switched on and after
t
completion of the test sequence, the causes of
the fault may be:
a - the voltage supply is less than 11 volts
An ABS fault is present. If an ABS fault is
present, the anti-lock brake system remains
b-
switched off while the conventional brake
system remains fully operational.
a wheel speed sensor fault existed after the
last vehicle start (sporadic fault). In case of a
wheel speed sensor fault, the ABS warning
c-
light goes out automatically after restarting the
vehicle and after a speed above 20 km/h is
reached.
Line interruption between dash panel insert
and control unit -J104- binder Current
d-
Flow Diagrams, Electrical Fault Finding and
Fitting Locations.
e - Dash panel insert defective
If the ABS warning light goes out but the
warning light for the hand brake/brake fluid
t
level (-K14/33-) remains lit -2-, the causes of
the fault may be:
a - the hand-brake is still applied
b- Brake fluid level too low
Line fault binder Current Flow Diagrams,
c - Electrical Fault Finding and Fitting
Locations.
If the ABS warning light -1- and the warning
light for the hand brake/brake fluid -2- do not
t
go out, then the ABS and EBD (Electronic
Brake pressure Distribution) have failed.
In this case, a change in braking behaviour can be
expected as the brake pressure on the rear wheels
is no longer regulated.
the switch -K14/33- for the warning light (-
d-
F9-) is defective or incorrectly adjusted
215
Vehicle fitted with ABS/EDL - EDL does not operate

t Vehicle system tester -V.A.G 1552-
t Diagnostic cable -V.A.G 1551/3-
Complaint: Vehicle EDL system does not operate
When dealing with this complaint a possible fault cause may be that the brake light switch is incorrectly set
or is not operating Chapter, set display group number 003 and brake light switch Chapter.
216
Perform self-diagnosis
Test requirements
l Approved tyre size fitted to all wheels; tyres inflated to the specified pressure.
Mechanical/hydraulic part of the brake system together with the brake light switch and brake lights
l
operating properly.
No leaks in hydraulic connections and lines (visual inspection of hydraulic unit, brake calipers, wheel
l
brake cylinders, tandem brake master cylinder).
l Wheel bearings and wheel bearing play O.K.
l Control unit correctly bolted to the hydraulic unit.
l Plug connection on control unit -J104- correctly plugged in (lock is engaged).
l Inspect plug contacts of ABS components for damage and correct fitting.
l All fuses according to current flow diagram O.K (to check remove fuses from the fuse holder).
l Supply voltage O.K. (minimum 10.0 V).
Connecting vehicle system tester -V.A.G 1552- and selecting function

Note
t During self-diagnosis the ABS function is disconnected in the control unit.

t After completing the repair and interrogating the fault memory, it can be erased.
When the ignition is switched off, connect

vehicle system tester -V.A.G 1552- with
diagnostic cable -V.A.G 1551/3- to the

diagnostic connector.
Interrogating control unit version
Readout on display: Vehicle system test

If no readout appears in the display, check plug connection for self-diagnosis HELP
- electrical test Chapter and further, test steps 14 and 15. Select function XX
217
Note
Additional operating instructions can be displayed via the HELP button of

t
the -V.A.G 1552- according to the program.
t The button is used for moving forward in the program.
Switch on ignition.
Readout on display:
Vehicle system test
Enter 03 for address word Brake electronics and confirm HELP
entry with key Q. Select function XX

Vehicles without CAN BUS
On the display appears, e.g. the display:
The display shows:
t the control unit identification number, e.g. 1J0907379
t the system designation, e.g. ABSITTAE20GI 1J0907379 ABS ITTAE20GI V00
t the version number, e.g. V00 ->
Coding 03604 WSC XXXXX
t the code No. of the control unit, e.g. 03604
the workshop code (WSC) Operating instructions vehicle
t
system tester V.A.G 1552
Vehicles with CAN BUS
On the display appears, e.g. the display: 1J0907379H ABS/EDL 20 IE CAN 0001 ->
Vehicles with MK 60 Coding 13504 WSC XXXXX
On the display appears, e.g. the display:
Assignment of the control unit electronic catalogue of original
parts.
Code the control unit Chapter.
If the control unit identification number is not displayed 1C0907379C ABS FRONT MK60 0102
Chapter. ->
Press key. Coding 0001025 WSC
Note XXXXX
After pressing the HELP button an overview of the possible

functions is displayed:
If the button is pressed, the programme returns to the initial
position.
Readout on display: Vehicle system test HELP
Overview of selectable functions Chapter. Select function XX
218
Overview of selectable functions
Page
00 - Automatic test sequence Chapter
01 - Interrogating control unit version Chapter
02 - Interrogating fault memory Chapter
03 - Actuator diagnosis Chapter
04 - Initiate basic setting 1) Chapter
05 - Erasing fault memory Chapter
06 - Ending output Chapter
07 - Coding control unit Chapter
08 - Reading measured value block Chapter
1)
only required for vehicles with EDL
Interrogating fault memory

Enter 02 for the function Interrogate fault memory and confirm HELP
Select function XX
the entry with the key Q.
X faults detected!
The number of stored faults or No fault recognised appears in the display.
Press button.
The stored faults are displayed in sequence.
No fault
Note the fault message displayed in the fault table Chapter. For MK60 detected!
Chapter.
If No fault detected, the program returns to its initial position after the button is
pressed:
Readout on display:
End output (function 06) Chapter.
Switch off ignition and disconnected vehicle system
tester.
Note
Vehicle system test

HELP
If a fault is detected: Select function XX
t 1. Rectify fault (repair)
t 2. Interrogate fault memory (function 02)
t 3. Erase fault memory (function 05)
t 4. End output (function 06)
t 5. Road test
t 6. Interrogate the fault memory again
Automatic test sequence
219
Note
With the automatic test sequence, all fault memory contents of the control units are interrogated.
Switch on ignition
Enter 00 for function Automatic test sequence and confirm HELP
Select function XX
entry with key Q.
The control unit identification is shown on the display. 1J0907379 H ABS/EDL 20 IE
After this all the control unit identifications with possible entries in the CAN 0001 ->
fault memories appear in the display. Coding 13504
WSC XXXXX
End output (function 06) Chapter.
Fault table
Note
As the control units are interlinked over a data BUS line, always start fault finding by activating the key
t function 00 Automatic test sequence on all control units fitted to the vehicle. This allows to interrogate
all the control units fitted in the vehicle in order to determine their possible faults.
All the possible faults which can be detected by the ABS control unit -J104- and can be displayed by the
t
-V.A.G 1552-, are listed according to their 5-digit fault code.
t The fault table may also display the fault type.
t The column Fault elimination refers to certain test steps in the electrical test.
Before replacing components found to be faulty, test all corresponding plug connections, lines and earth
t connections according to the current flow diagram binder Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations
After carrying out the repair, always interrogate and erase the fault memory using the vehicle system
t
tester -V.A.G 1552- and perform a test drive (at a speed above 20 km/h).
t After the test drive interrogate the fault memory again.
Readout on Possible cause of fault Rectifying fault
display
-V.A.G 1552-
No fault If after repair No fault detected is displayed, the self-diagnosis is completed. If the ABS
detected does not operate without fault in spite of the display read-out No fault detected, proceed as
follows: 1. Perform a test drive at a speed above 20 km/h, 2. Interrogate the fault memory
again, if still no fault is stored, 3. continue fault finding without self-diagnosis and perform
the electrical test completely Chapter.
00283 Open circuit, short-circuit to positive or Inspect wiring and plug connections according
Front left to earth or loose contact in the wiring to the current flow diagram binder Current
t
wheel speed between wheel speed sensor -G47- and Flow Diagrams, Electrical Fault Finding and
sensor -G47- ABS control unit -J104- Fitting Locations
Perform electrical Test Chapter.
Damage to the pulse rotor or to the Check the wheel speed sensor -G47- and the
t
wheel speed sensor -G47- pulse rotor for damage.
t Wheel speed sensor coil -G47- defective Replace pulse rotor or wheel speed sensor

-G47- Chapter and Chapter.
220
t ABS control unit -J104- defective If the fault occurs again:
Replace ABS control unit -J104- Chapter.

display -V.A.G
1552-
00283 Open circuit, short-circuit to positive or Inspect wiring and plug connections
Front left wheel to earth or loose contact in the wiring according to the current flow diagram
t
speed sensor between wheel speed sensor -G47- and binder Current Flow Diagrams,
-G47- ABS control unit -J104- Electrical Fault Finding and Fitting
signal outside Locations
the tolerance 1) Perform electrical Test Chapter.
Electrical malfunctions due to external Reading measured value block Chapter

t interference (high-frequency irradiation, display group number 001.
e.g. non-insulated ignition cable)
Damage to the pulse rotor or to the wheel Check the wheel speed sensor -G47- and
t
speed sensor -G47- the pulse rotor for damage.
Air gap between wheel speed sensor Replace pulse rotor or wheel speed sensor

t -G47- and pulse rotor too great (signal -G47- Chapter and Chapter.
N.O.K.)
00283 Air gap between wheel speed sensor Check the installation of the wheel speed
Front left wheel t -G47- and pulse rotor too great (signal sensor -G47- and the pulse rotor Chapter
speed sensor N.O.K.) and Chapter.
-G47- Reading measured value block Chapter;
mechanical fault
display group number 002.
1)
Performing actuator diagnosis Chapter.
Exhaust valves in the hydraulic unit If the fault occurs again:
t
-N55- defective Replace hydraulic unit -N55- Chapter.
1)
The type of fault can only be detected as of 20 km/h (perform test drive).

display -V.A.G
1552-
Front right to earth or loose contact in the wiring according to the current flow diagram
t
wheel speed between wheel speed sensor -G45- and binder Current Flow Diagrams,
sensor -G45- ABS control unit -J104- Electrical Fault Finding and Fitting
Locations
Damage to the pulse rotor or to the Check the wheel speed sensor -G45- and
t
wheel speed sensor -G45- the pulse rotor for damage.

Replace ABS control unit -J104-

Chapter.
00285 t Open circuit, short-circuit to positive or
Inspect wiring and plug connections
Front right
221
speed sensor to earth or loose contact in the wiring according to the current flow diagram
-G45- between wheel speed sensor -G45- and binder Current Flow Diagrams,
signal outside ABS control unit -J104- Electrical Fault Finding and Fitting
the tolerance 1) Locations.
Electrical malfunctions due to external Reading measured value block Chapter;

t

N.O.K.)
Front right t -G45- and pulse rotor too great (signal sensor -G45- and the pulse rotor Chapter
speed sensor N.O.K.) and Chapter.
-G45- Reading measured value block Chapter;
mechanical fault
1)
t
1)
The fault can only be detected as of 20 km/h (perform test drive).

display -V.A.G
1552-
Rear right wheel to earth or loose contact in the wiring according to the current flow diagram
t
Locations.
t


Chapter.
Rear right speed to earth or loose contact in the wiring according to the current flow diagram
t
sensor -G44- between wheel speed sensor -G44- and binder Current Flow Diagrams,
signal outside ABS control unit -J104- Electrical Fault Finding and Fitting
1)
the tolerance Locations.

222
t

N.O.K.)
Rear right speed t -G44- and pulse rotor too great (signal sensor -G44- and the pulse rotor Chapter
sensor -G44- N.O.K.) and Chapter.
mechanical fault Reading measured value block Chapter;
1)
t
1)

display -V.A.G
1552-
Speed sensor to earth or loose contact in the wiring according to the current flow diagram
t
rear left -G46- between wheel speed sensor -G46- and binder Current Flow Diagrams,
ABS control unit -J104- Electrical Fault Finding and Fitting
Locations.
Damage to the pulse rotor or to the wheel Check the wheel speed sensor -G46- and the
t
speed sensor -G46- pulse rotor for damage.


Chapter.
Rear left wheel to earth or loose contact in the wiring according to the current flow diagram
t
signal outside Locations.
the tolerance 1) Perform electrical Test Chapter.

Damage to the pulse rotor or to the wheel Check the wheel speed sensor -G46- and the
t
speed sensor -G46- pulse rotor for damage.

N.O.K.)
Rear left speed t -G46- and pulse rotor too great (signal sensor -G46- and the pulse rotor Chapter
sensor -G46- N.O.K.) and Chapter.
223
mechanical fault Reading measured value block Chapter;
1)
t
1)

display -V.A.G
1552-
00668 Open circuit, short-circuit to positive Inspect wiring and plug connections according
t
Onboard or earth to the current flow diagram binder Current

voltage tml. 30 Flow Diagrams, Electrical Fault Finding and
signal outside Fitting Locations
the tolerance Perform electrical test Chapter and continue.
01044 ABS control unit -J104- incorrectly Check coding of the ABS control unit -J104-
t
Control unit coded Chapter
wrongly coded Bridge in the multi-pin connector to Inspect wiring and plug connections according
the ABS control unit -J104- from to the current flow diagram binder Current
t
contact 3 to contact 14 interrupted or Flow Diagrams, Electrical Fault Finding and
short-circuited Fitting Locations.
Perform electrical test Chapter and

continue.
01130 Electrical malfunctions due to Erase fault memory.
ABS operation external interference (high-frequency Perform a test drive at a speed above 20 km/h.
t
implausible irradiation, e.g. non-insulated ignition Interrogate the fault memory again.
signal1) cable)
Open circuit, short-circuit to positive Inspect wiring and plug connections according
t
or earth to the current flow diagram binder Current
Fitting Locations.
Perform electrical test Chapter and

continue.
Replace ABS control unit -J104- Chapter.
01276 Plug connection E-engine to control Performing actuator diagnosis Chapter.
t
ABS hydraulic unit
pump -V64-
signal outside
the tolerance 1)
Open circuit, short-circuit to positive Inspect wiring and plug connections according
t
or earth to the current flow diagram binder Current
Fitting Locations.
t ABS hydraulic pump -V64- defective If the hydraulic pump -V64- starts without
fault when carrying out the test step no. 18 in
the electrical test Chapter, then the ABS
control unit must be replaced -J104-.
224
t ABS control unit -J104- defective Replace ABS control unit -J104- Chapter.
1)
Readout on display Possible cause of fault Rectifying fault

-V.A.G 1552-
01312 ABS control unit -J104- Check coding of the ABS control unit -J104-
t
Databus drive incorrectly coded Chapter
1)
defective
or
Engine control unit Check engine control unit Rep. gr. 01 of the
t
incorrectly coded relevant engine identification character
Open circuit, short-circuit Inspect wiring and plug connections according to the
t
to positive or earth current flow diagram binder Current Flow

Diagrams, Electrical Fault Finding and Fitting
Locations.
Perform electrical test Chapter and continue.
Databus drive Ignition key turns too Erasing fault memory Chapter
t
defective 1) slowly in the ignition lock No further measures required.
sporadic Inform customer (inform).
01314 Open circuit in the data Check databus cables and plug connections according
Engine control unit t BUS lines, short-circuit to to the current flow diagram binder Current Flow

no communication positive or to earth Diagrams, Electrical Fault Finding and Fitting
Locations
Gearbox control t BUS lines, short-circuit to to the current flow diagram binder Current Flow

unit 2) positive or to earth Diagrams, Electrical Fault Finding and Fitting
no communication Locations
Brake control unit t BUS lines, short-circuit to to the current flow diagram binder Current Flow

no communication positive or to earth Diagrams, Electrical Fault Finding and Fitting
Locations
1)
The fault data BUS drive defective does not result in the ABS warning light -K47- or the hand
brake/brake fluid level warning light -K14/33- lighting up. The ABS function is fully maintained.
2)
Only on vehicles with automatic gearbox.

-V.A.G 1552-
18256 Fault entry in 4AV Read out fault memory of the engine control unit
t
Please read out fault control unit Rep. gr. 01 of the relevant engine identification
memory of the engine character
CU
225
65535 ABS control unit Replace control unit -J104- Chapter.
t
Control unit defective -J104- defective
Erasing fault memory
Requirements:
l Fault memory was interrogated
Press key.
Enter 05 for the function Erase fault memory and confirm the HELP
Select function XX
entry with the key Q.
Readout on display: Vehicle system test ->
Press key. The fault memory is erased
Readout on display:
Vehicle system test HELP
Note
Select function XX
Vehicle system test

If this readout appears in the display then the test sequence is HELP
t
incorrect. Select function XX
Carefully follow the test sequence step by step: first interrogate the Caution!
t Fault memory was not
fault memory, then erase.
interrogated
Ending output
Enter 06 for the function End output and confirm with the key Q.
Readout on display:
Switch off ignition.
Vehicle system test
Disconnect plug connection from vehicle system tester. HELP
Switch on ignition. Select function XX
The ABS warning light -K47- and the hand brake/brake fluid level warning
light -K14/33- must go out after approx. 2 seconds.
Coding control unit

The control unit built into the vehicle is coded. New control units supplied by the spare part storeroom are
not coded and must be recoded after being installed
Coding requirements
The coding is only possible if the workshop code (WSC) is entered in the vehicle system tester -V.A.G
1552-.
Test sequence
Determine the engine identification characters and the type of ABS hydraulic control unit fitted on the
226
vehicle.
Connect the vehicle system tester -V.A.G 1552- and enter the address word 03 brake electronics with
the ignition switched on Chapter.

Enter 07 for the function Coding control unit and confirm the HELP
Select function XX
entry with key Q.
Readout on display:
Enter the correct code number for the vehicle and confirm Code control unit
Q
with key Q. Enter code number XXXXX (0-
Table of codes Chapter. 32767)
Table of codes
Code number - model year
Engine identification characters Engine ABS version 1997 1998 1999 2000 2001
AMD 1,4 Itr./44 kW ABS 03604 03604
AMD 1,4 Itr./44 kW ABS/EDL 03604 03604
AEE 1,6 Itr./55 kW ABS 03604 03604 03604 03604
AEE 1,6 Itr./55 kW ABS/EDL 03604 03604 03604 03604
AEH 1,6 Itr./74 kW ABS 03604 03504 03504 03504
AEH 1,6 Itr./74 kW ABS/EDL 03604 13504 13504 13504
AGN 1,8 Itr./92 kW ABS 03604 03504 03504
AGN 1,8 Itr./92 kW ABS/EDL 03604 13504 13504
AGU 1,8 Itr./110 kW ABS 03504 03504 03504
AGU 1,8 Itr./110 kW ABS/EDL 13504 13504 13504
AGP 1.9 Itr./50 kW ABS 03604 03604 03304 03304
AGP 1.9 Itr./50 kW ABS/EDL 03604 03604 03304 03304
AGR 1.9 Itr./66 kW ABS 03604 03504 03304 03304
AGR 1.9 Itr./66 kW ABS/EDL 03604 13504 13304 13304
AHF 1.9 Itr./81 kW ABS 03604 03504 03304 03304
AHF 1.9 Itr./81 kW ABS/EDL 03604 13504 13304 13304
AQY 2.0 ltr./85 kW ABS 03304
AQY 2.0 ltr./85 kW ABS/EDL 13504
ARX 1.8 ltr./110 kW 4x4 13504
AGR 1.9 ltr./66 kW 4x4 13504 13504
ATD 1.9 ltr./74 kW 4x4 13504
AZJ 2.0 ltr./85 kW 4x4 13504

The control unit coding appears in the display, e.g. 03604: 1J0907379 A ABS/EDL ITT AE 20 GI V00 ->
Vehicles with CAN BUS Coding 03604 WSC XXXXX
The control unit coding appears in the display, e.g. 1J0907379 H ABS/EDL 20 IE CAN 0001
13504: ->
Continued for all vehicles Coding 13504 WSC
XXXXX
Press key.
Readout on display: Vehicle system
test
Enter 06 for the function End output and confirm with the key Q. HELP
Note Select function XX
227
The ABS warning light -K47- and the hand brake/brake fluid level warning light
t -K14/33- will light up and will remain lit up if the control unit is incorrectly
coded.
There is a simultaneous entry in the fault memory Chapter; interrogate fault
t
memory 02.
If the control unit is coded with an approved code, no fault entry is made in the
t
fault memory and the ABS warning light does not flash.
If the control unit is not coded (Code 00000), the ABS warning light -K47- and
t the hand brake/brake fluid level warning light flash -K14/33- (once per second).
In this case no entry is made in the fault memory.
Reading measured value block

The control unit can transmit many measured values. These measured values provide information about the
operating condition of the system or the connected sensors. In many cases the transmitted measured values
are useful for fault finding and fault elimination. As all measured values cannot be analysed
simultaneously, they are concentrated in individual display groups which can be selected via display group
numbers.
Safety measures
If test and measuring devices are required during test drives observe the following:
Always secure the test and measuring devices on the rear seat and have a second person operate them
t
there.
If the test and measuring devices are operated from the passenger seat, the passenger could be injured by
t
the release of the passenger airbag in the event of an accident.
Test sequence and test table with measured values
Connect the vehicle system tester -V.A.G 1552- and enter the address word 03 brake electronics with
the ignition switched on Chapter.

Readout on display:
Enter 08 for the function Read measured value block and Vehicle system test
confirm the entry with Q. HELP

Test of the wheel speed sensor assignment Select function XX
Display group number 001:
Readout on display: Reading measured value block
Enter 01 for the display group number 01 and confirm entry with Enter display group number
XXX
key Q.
Reading measured value block 1
In the measured value block there are always 4 display fields ->
-arrows- 1 through 4. ->1 ->2 ->3
->4
Read-out on display: (stationary vehicle)
Reading measured
The current wheel speeds are displayed. They serve to check the wheel speed value block 1 ->
sensor assignment to the wheel. (To this end raise the vehicle and turn the wheel 0 km/h 0 km/h 0 km/h
by hand.) 0 km/h
Example:
Read-out on display: (moving wheels) Reading measured value block 1
->
The current front right wheel speed is displayed. 0 km/h 4 km/h 0 km/h 0 km/h
To this end raise the vehicle and have a second mechanic turn the
228
wheel by hand.
Display field Denomination Readout on -V.A.G 1552-
1 Front left wheel speed (km/h) 0 ... 255 1)
2 Front right wheel speed (km/h) 0 ... 255 1)
3 Rear left wheel speed (km/h) 0 ... 255 1)
4 Rear right wheel speed (km/h) 0 ... 255 1)
Press the key C.

If the button is pressed, subsequently enter 08 in order to return to the work sequence Read measured
value block.
Testing the wheel speed sensor
Display group number 002:
Readout on display: Reading measured
Enter 02 for the display group number 02 and confirm entry with key Q. value block
The ABS control unit stores the first usable voltage signals from the wheel speed Enter display
group number XXX
sensor when starting and displays them as fixed values in the measured value block.
In the measured value block there are always 4 display fields -arrows-
1 through 4.
The values displayed in the display field 1 and 2 must on no account
be above 6 km/h.
The values displayed in the display field 3 and 4 must on no account
be above 2 km/h.
If the values are more, a fault can be present in the installation of the Reading measured value block
2 ->
wheel speed sensor.
->1 ->2 ->3
Possible causes of fault: ->4
t Air gap between wheel speed sensor and pulse rotor too great.
Check if the wheel speed sensor is correctly bolted to the wheel
bearing housing.
Exterior damage to the wheel speed sensor or the pulse rotor (change
t
damaged component).
Replace the damaged component.
Display field Denomination Readout on -V.A.G 1552-
1 Front left wheel speed (km/h) 0 ... 255
2 Front right wheel speed (km/h) 0 ... 255
3 Rear left wheel speed (km/h) 0 ... 255
4 Rear right wheel speed (km/h) 0 ... 255
Readout on display (stationary vehicle):

Drive off slowly until values are displayed on the display of the
vehicle system tester -V.A.G 1552-. Reading measured value

Deviations of the display fields 1 and 2 within 6 km/h are O.K. (see block 2 ->
example). 255 km/h 255 km/h 255 km/h
255 km/h
Deviations of the display fields 3 and 4 within 2 km/h are O.K. (see
example).
Example:
Read-out on display (when starting slowly): Reading measured value
Press the key C. block 2 ->
If the button is pressed, subsequently enter 08 in order to return to the 3 km/h 6 km/h 2 km/h 1
km/h
work sequence Read measured value block.
229
Test of the brake light switch for the ABS and the ABS/EDL function
Display group number 003
Enter 03 for the display group number 03 and confirm entry with Enter display group number
XXX
key Q.
Reading measured value block 3
In the measured value block there are always 4 display fields ->
-arrows- 1 through 4. ->1 ->2 ->3
->4
Reading measured value block 3 ->
Readout on display: 0
Display field Test conditions Readout on -V.A.G 1552-
1 t Brake pedal not actuated not activated
t Brake pedal actuated activated
2 not assigned
3 not assigned
4 not assigned
If the display of the -V.A.G 1552-, despite the foot brake activated -0- or the foot brake not activated -1-,
is:
There is also the possibility that the brake light switch is not correctly set Chapter.
Enter 06 for the function End output and confirm with the key Q.
Actuator diagnosis

The final control diagnosis is a part of the electrical test. The final control diagnosis is used to test the
pump motor, it is also used to check the correct operation of the hydraulic circuits (assignment of brake
pressure lines to the wheel brakes, and also the operation of the valves) to ensure they are correctly
connected and are not leaking.
Note
The vehicle must be raised so that the wheels are clear of the ground (2nd mechanic required for rotating
t
the wheels).
t It is possible to quit the test sequence at any time by pressing key -C-.
After depressing the brake pedal several times, the vacuum in the brake servo unit is reduced. Greater
t effort is then required to operate the brake pedal in order to achieve the same fluid pressure in the brake
system as with vacuum assistance.
Once the vacuum in the brake servo unit has been reduced, it is possible that the wheels do not lock
t
start engine in order to build up vacuum in the brake servo unit.
t Operate the vehicle system tester by referring to the read-out on the display.
Example:
Read-out on display of vehicle system tester -V.A.G 1552- during the final control diagnosis
(e.g. front left wheel, FL)
Final control diagnosis - ->
IFL = Inlet valve front left IFL:VBAT OFL:0V Wheel FL locked
VBAT = V-Battery voltage, voltage present on valve
230
OFL = Outlet valve front left
0V = 0 Volt; no voltage on valve
locked/free = Wheel status; must be checked by 2nd mechanic
Hydr-P = Hydraulic pump Final control diagnosis
Performing actuator diagnosis - ->
Connect the vehicle system tester -V.A.G 1552- and enter the address EDL valves/Hydr.p: VBAT
word 03 brake electronics with the ignition switched on Chapter. Wheel FL/FR block
Enter 03 for the function Actuator diagnosis. Select function XX
Readout on display:
Confirm the entry with key Q
The ABS hydraulic pump -V64- must run. Vehicle system test
Note Q
03-Actuator diagnosis
During the next work steps, the ABS warning light flashes 2 times and the
hand brake/brake fluid level warning light flashes 4 times per second.
Readout on display: Final control diagnosis - ->
Press the button within the next 60 seconds. Hydraulic pump ABS -V64
Readout on display:
Actuate brake pedal. Operate brake
Press key.
Readout on display:
Instruct the 2nd mechanic to rotate the relevant wheel by hand. Final control diagnosis
- ->
If the wheel does not lock, it is possible that there is a fault in the IFL: 0V OFL: 0V Wheel FL
mechanical/hydraulic part of the brake system. locked
Press key.
Readout on display:
Press key. Final control diagnosis
The ABS hydraulic pump -V64- must run - ->
Brake pedal must not yield. IFL: 0V OFL: 0V Wheel FL
locked
If the brake pedal yields, there is a fault in the hydraulic unit. If this is
the case replace the hydraulic unit Chapter.
Readout on display:
If the wheel does not lock, it is possible that there is a fault in the - ->
mechanical/hydraulic part of the brake system. IFL: 0V OFL: VBAT Wheel FL
free
Press key.
ABS hydraulic pump -V64- no longer runs
Readout on display:
- ->
Brake pedal must be felt to yield. IFL: 0V OFL: 0V Wheel FL
If the brake pedal does not yield, there is a fault in the hydraulic unit. If free
this is the case replace the hydraulic unit Chapter.
Readout on display:
- ->
If the wheel does not lock, it is possible that there is a fault in the IFL: 0V OFL: 0V Wheel FL
Press key.
Readout on display: Final control diagnosis - ->
231
Take your foot off the brake pedal. Release brake
Press key.
Readout on display:
Actuate brake pedal. Release brake
Press key.
Readout on display:
The ABS hydraulic pump -V64- must run. - ->
Brake pedal must not yield. IFR: 0V OFR: 0V Wheel FR
locked
Readout on display:
- ->
Brake pedal must be felt to yield. IFR: 0V OFR: 0V Wheel FR
If the brake pedal yields, there is a fault in the hydraulic unit. If this is free
Readout on display:
- ->
If the wheel does not lock, it is possible that there is a fault in the IFR: 0V OFR: 0V Wheel FR
Press key.
Readout on display:
Press key.
Readout on display:
Actuate brake pedal Operate brake
Press key.
Readout on display:
- ->
If the wheel does not lock, it is possible that there is a fault in the IRL:0V ORL:0V Wheel RL
Press key.
Readout on display:
The ABS hydraulic pump -V64- must run. - ->
Brake pedal must not yield. IRL:VBAT ORL:0V Wheel RL
locked
Readout on display:
If the wheel locks, it is possible that the brake pressure lines to the - ->
wheel brakes are wrongly connected. IRL:VBAT ORL:VBAT Wheel RL
free
Press key.
ABS hydraulic pump -V64- no longer runs.
Readout on display:
- ->
Brake pedal must be felt to yield. IRL:VBAT ORL:0V Wheel
If the brake pedal does not yield, there is a fault in the hydraulic unit. If RL free
Readout on display: Final control diagnosis
- ->
232
Instruct the 2nd mechanic to rotate the relevant wheel by hand.
If the wheel does not lock, it is possible that there is a fault in the IRL:0V ORL:0V Wheel RL
Press key.
Readout on display:
Press key.
Readout on display:
Actuate brake pedal Operate brake
Press key.
Readout on display:
- ->
If the wheel does not lock, it is possible that there is a fault in the IRR:0V ORR:0V Wheel RR
Press key.
Readout on display:
The ABS hydraulic pump -V64- must not run. - ->
Brake pedal must not yield. IRR:VBAT ORR:0V Wheel RR
locked
Readout on display:
If the wheel locks, it is possible that the brake pressure lines to the - ->
wheel brakes are wrongly connected. IRR:VBAT ORR:VBAT Wheel RR
free
Press key.
ABS hydraulic pump -V64- no longer runs.
Readout on display:
- ->
Brake pedal must be felt to yield. IRR:VBAT ORR:0V Wheel
If the brake pedal does not yield, there is a fault in the hydraulic unit. If RR free
Readout on display:
- ->
If the wheel does not lock, it is possible that there is a fault in the IRR:0V ORR:0V Wheel RR
Press key.
Readout on display:
Press key.
Read-out on display: (for vehicles with EDL)
If the wheels do not lock, there is a fault in the hydraulic part of the ABS - ->
system. If this is the case replace the hydraulic unit Chapter. EDL valves/ Hydr.p:VBAT
Wheel FL/FR block.
Press key.
The ABS warning light -K47- goes out.
Readout on display: Function unknown or cannot - ->
Note be carried out at the moment
The final control diagnosis is completed

233
Press key.
Readout on display:
Note
Vehicle system test

If the ABS warning light does not go out, there is a fault in the HELP
t
system. Select function XX
Carefully follow the test sequence step by step: first interrogate the
t
fault memory, then erase.
Ending output Chapter.
Basic setting

t Diagnostic cable -V.A.G 1551/3, 3A, 3B oder 3C-
On models with EDL, the basic setting is used for bleeding the hydraulic unit.
It is only necessary to carry out the basic setting if at least one chamber of the brake fluid reservoir has run
completely empty (e.g. leakage in the brake system).
Note
Operate the vehicle system tester by referring to the read-out on the display.
WARNING
When replenishing brake fluid with a brake filling and bleeding appliance, it is important to ensure that the
filling pressure of 0.1 MPa is not exceeded.
If the filling pressure of 0.1 MPa (1 bar) is exceeded, proper bleeding of the hydraulic unit is no longer
assured.
Connect the brake filling and bleeding device.
Connect vehicle system tester -V.A.G 1552- and enter the address word 03 - brake electronics - with the
ignition switched on Chapter.

Enter function 04 Initiate basic setting. Select function XX
Readout on display: Vehicle system test Q
Confirm the entry with the key Q. 04 - Basic setting
Readout on display:
Enter 001 Enter display group number XXX
Confirm the entry with the key Q.
Readout on display:
t Pedal yields. System in basic setting
t Hydraulic pump starts running. Depress pedal and hold...
t Pedal moves back.
Readout on display: System in basic setting
Release pedal;FR+FL bleeder screws
Press button.
OPEN
Note
234
If you are using the -V.A.G 1551- a -3- appears instead of
the .
Readout on display:
t Hydraulic pump starts running. System in basic setting 2
Readout on display: Please wait . . . (10 sec.)
Press button.
Readout on display:
t Pedal yields. System in basic setting 3
t Pedal moves back.
Readout on display: System in basic setting 3
Press button. Release pedal;FR+FL bleeder screws OPEN
t Hydraulic pump starts running. Please wait . . . (10 sec.)
Press button. Actuate pedal 10x; Bleeder screws CLOSED
Readout on display:
t Pedal moves back.
Readout on display:
t Pedal moves back.
Readout on display:
t Pedal moves back.
Readout on display:
t Pedal moves back.
235
Readout on display:
t Pedal moves back.
System in basic setting 13
Readout on display: Release pedal;FR+FL bleeder screws OPEN
Readout on display:
t Pedal moves back.
Readout on display: Release pedal;FR+FL bleeder screws OPEN
Readout on display: Part bleeding ended...
Enter 06 for the function End output. Select function XX
Readout on display: Vehicle system test Q
Confirm the entry with the key Q. 06 - End output
Readout on display:
Switch off ignition. Vehicle system test HELP
Disconnect the plug connection -V.A.G 1552-. Enter address word XX
Bleed brake system.
236
Electrical test of the ABS and ABS/EDL ITT Mark 20 IE

t Test box -V. A.G 1598/21-
t Measuring tool set -V.A.G 1594 A-
t Handheld multimeter, e.g. -V.A.G 1526 A-
The test steps as of Chapter apply to:
Vehicles for which the final control diagnosis does not indicate the fault source. In this case the full
t
electric inspection must be carried out.
Vehicles for which the final control diagnosis does give a direct indication of the fault source. Then only
t
perform the test steps recommended in the fault table (targeted approach).
Test conditions
The fuses must be OK in compliance with the current flow diagram binder Current Flow Diagrams,
l Electrical Fault Finding and Fitting Locations To check, remove fuses from the fuse holder on the
battery and the fuse holder on the left of the dash panel.
Before starting the test switch off the ignition and electrical consumers (headlights, lighting, blowers
l
etc.).
Remove the multi-pin plug connection from the

ABS control unit -J104- and connect the test
l
box -V.A.G 1598/21--1- to the plug of the
wiring loom -2-.
The specified values are specific to the -V.A.G
1526 A- and do not necessarily apply for other
measuring tools.
Multi-pin plug connection with contact assignment
Note
All unlisted contacts are not yet assigned and must under no circumstances be connected to other
components!
237
Contact assignment of the multi-pin plug
connection -T25- wiring loom / ABS control unit
-J104-
Contac
Wiring to component ...
t
1 Front left speed sensor -G47-
3 Jumper to contact -14-
4 Voltage supply terminal -15-
5 Rear left wheel speed sensor -G46-
7 Plug connection -T16a/7 K- - cable
8 Earth terminal 31
9 Voltage supply of battery +
10 Data BUS cable (CAN-L) binder Current Flow Diagrams, Electrical Fault Finding and Fitting
Locations
11 Data BUS cable (CAN-H) binder Current Flow Diagrams, Electrical Fault Finding and Fitting
Locations
14 Jumper to contact 3
16 ABS warning light
18 Brake light switch -F-
19 Front right speed sensor -G45-
22 Rear right wheel speed sensor -G44-
24 Left earth point under battery
25 Voltage supply of battery +
238
Contact assignment of the plug connections for
the voltage supply and the self-diagnosis with the
vehicle system tester -V.A.G 1552-
Contact 4 = Earth (terminal 31)
Contact 5 = Earth (terminal 31)
Contact 16 = Positive (terminal 30)
Contact 7 = -K- cable via cable connection -
diagnosis - to ABS control unit -J104- contact 7
239
Overview of test steps
Test steps in the test table

Component to be tested
Chapter
Voltage supply of the ABS hydraulic pump -V64- to the ABS control unit - Perform test step 1.
-J104-
Voltage supply of the valves in the hydraulic unit -N55- to the ABS control - Perform test step 2.
unit -J104-
Voltage supply (terminal 15) to the ABS control unit -J104- - Perform test step 3.
Function of the brake light switch -F- - Perform test step 4.
Resistance of the front right speed sensor -G45- - Perform test step 5.
Resistance of the front left speed sensor -G47- - Perform test step 6.
Resistance of the rear right speed sensor -G44- - Perform test step 7.
Resistance of the rear left speed sensor -G46- - Perform test step 8.
Voltage signal of the front right speed sensor -G45- - Perform test step 9.
Voltage signal of the front left speed sensor -G47- - Perform test step 10.
Voltage signal of the rear right speed sensor -G44- - Perform test step 11.
Voltage signal of the rear left speed sensor -G46- - Perform test step 12.
Jumper - Perform test step 13.
Voltage supply for -V.A.G 1552-, plug connection -T16- - Perform test step 14.
Resistance of the K cable for -V.A.G 1552-, plug connection -T16- - Perform test step 15.
Function of the ABS warning light -K47- - Perform test step 16.
Function of the hand brake/brake fluid level warning light -K14/33- - Perform test step 17.
Function of the ABS hydraulic pump -V64- - Perform test step 18.
Checking the databus cables - Perform test step 19.
Test table
The denominations of the bushes of the test box -V.A.G 1598/21- are identical to the contact
t denominations of the ABS control unit -J104- in the current flow diagram binder Current Flow
Diagrams, Electrical Fault Finding and Fitting Locations
If the measured values deviate from the nominal values, perform the fault eliminating measures listed in
t
the right part of the table.
t Once these values are reached, additionally check the cables for short-circuit to positive and earth.
t Electrical continuity tests with the measuring tool set -V.A.G 1594 A- (bridge structure).
If the measured values only differ slightly from the specified values, clean the bushes and plugs of the
test devices and measuring cables (e.g. with contact spray) and repeat test. Before replacing the relevant
t
components test the cables and connections more specifically for nominal values below 10 , repeat the
resistance measurement on the component.
Switch on measuring range: voltage measurement (20 V =)
Test -V.A.G Test covers Test Specified Measures for deviations from nominal
l
step 1598/21- conditions value value
bushes additional

works
1 8 + 25 Voltage supply of the l Ignition off 10.0-14.5V Test wiring of contact 8 to earth.
ABS hydraulic pump Test wiring of contact 25 via the
-V64- to the ABS
240
control unit -J104- fuse to battery positive binder
Current Flow Diagrams, Electrical
Fault Finding and Fitting
Locations
2 9 + 24 Voltage supply of the l Ignition off 10.0-14.5V Test wiring of contact 24 to earth.
valves in the ABS Test wiring of contact 9 via the fuse
hydraulic unit -N55- to to battery positive binder
the control unit -J104-
Locations
3 4+8 Voltage supply l Ignition on 10.0-14.5V Test wiring of contact 8 to earth.
(terminal 15) to the Test wiring of contact 4 to the
control unit -J104- connector of terminal 15 (relay
plate).
4 8 + 18 Function of the brake l Ignition off 0,0-0,5 V Test fuses.
light switch -F- Brake pedal Test brake light switch -F- and read
l
not actuated measured value block Chapter;
display group number 003
Test wiring of contact 8 to earth.
Test wiring of contact 18 to the
brake light switch binder

Locations
Actuate approx. Check brake light switch -F-

brake pedal. battery Chapter.
voltage
Switch on measuring range: resistance measurement (2 k)

Test -V.A.G Test covers Test Specified Measures for deviations from nominal
l
step 1598/21- conditions value value
bushes additional

works
5 19 + 20 Resistance of the l Ignition off 1,0 ... 1.3 Disconnect plug connection on speed

front right speed k sensor -G45-.
sensor -G45- Test the wiring according to the current
flow diagram binder Current Flow
Diagrams, Electrical Fault Finding and
Fitting Locations
Throughout the test, move cables (loose

contact).
If the lines are not found to be faulty:

Replace speed sensor -G45- Chapter.
6 1 +2 Resistance of the l Ignition off 1,0 ... 1.3 Disconnect plug connection on speed

front left speed k sensor -G47-.
Fitting Locations
241

contact).

7 22 + 23 Resistance of the l Ignition off 1,0 ... 1.3 Disconnect plug connection on speed

rear right speed k sensor -G44-.
Fitting Locations

contact).

8 5+6 Resistance of the l Ignition off 1,0 ... 1.3 Disconnect plug connection on speed

rear left speed k sensor -G46-.
Fitting Locations

contact).

Switch on measuring range: voltage measurement (2 V )

Test -V.A.G Test covers l Test conditions Specified value Measures for deviations from nominal
step 1598/21- additional value
bushes
works
9 19 + 20 Voltage signal l Vehicle raised Check the installation of the wheel
of the front l Ignition off speed sensor -G45- and the pulse
right speed rotor.
sensor -G45- Turn front right Alternating Check wheel speed sensor -G45- to
wheel by voltage min. ensure it is correctly connected
1
65 mV
approx. 1 /s read measured value block,
Chapter, display group number
001
10 1+2 Voltage signal l Vehicle raised Check the installation of the wheel
of the front left l Ignition off speed sensor -G47- and the pulse
speed sensor rotor.
-G47- Turn front left Alternating Check wheel speed sensor -G47- to
wheel to voltage min. ensure it is correctly connected
65 mV
approx. 1 1/s read measured value block,
001.
11 22 + 23 Voltage signal l Vehicle raised Check the installation of the wheel
242
of the rear right l Ignition off speed sensor -G44- and the pulse
speed sensor rotor.
-G44- Turn rear right Alternating Check wheel speed sensor -G44- to
wheel by voltage min. ensure it is correctly connected
190 mV
001.
12 5+6 Voltage signal l Vehicle raised Check the installation of the wheel
of the rear left l Ignition off speed sensor -G46- and the pulse
speed sensor rotor.
-G46- Turn rear left Alternating Check wheel speed sensor -G46- to
wheel to voltage min. ensure it is correctly connected
190 mV
001.
Switch on measuring range: resistance measurement (200 )

Test -V.A.G Test Test Specified Measures for deviations from nominal value
l
step 1598/21- covers conditions value
bushes additional

works
13 3+14 Jumper l Ignition off 0.0 - 1.0 Check the cables and the contacts in the plug
binder Current Flow Diagrams, Electrical
Fault Finding and Fitting Locations
If there is a deviation from the specified value:

Replace jumper.

Test -V.A.G Test covers l Test conditions Specified Measures for deviations from
step 1598/21- additional works value nominal value
bushes
14 - Voltage supply for l Ignition off 10.0 - Test wiring of -T16a/4- to

-V.A.G 1552-, Connect the handheld 14.5 V earth.
plug connection multimeter -V.A.G 1552 Test wiring of -T16a/16- via
-T16a-1)
A- with the measuring fuse to terminal 30 binder

tool set -V.A.G 1594 A- to Current Flow Diagrams,
-T16a-1) Electrical Fault Finding and
Fitting Locations
Contact 4 - earth
contact 16 - positive
1)
Chapter, contact assignment of the plug connection for the voltage supply and the self-diagnosis with
the vehicle system tester -V.A.G 1552-.

Test -V.A.G Test covers l Test conditions Specified Measures for deviations
step 1598/21- additional works value from nominal value
243
bushes
15 - Resistance of the l Ignition off max. 1.5 Check the cables of
-K- cable for Disconnect the multi-pin plug -T16a/7- via wiring
-V.A.G 1552-, connection from the ABS -Diagnose - an Kontakt 7-
plug connection
control unit -J104-. binder Current Flow
-16a-1) Connect test box V.A.G Diagrams, Electrical Fault
Finding and Fitting
1598/21.
Connect the handheld Locations
multimeter -V.A.G 1526- with
the measuring tool set -V.A.G

1594- to the contacts -T16/7-1)
and -T25/7- of the multi-pin
plug connection from the ABS
control unit -J104-.
1)
Chapter, contact assignment of the plug connection for the voltage supply and the self-diagnosis with
the vehicle system tester -V.A.G 1552-.
Functional test: ABS warning light -K47-

Test -V.A.G Test covers Test Specified value Measures for deviations from nominal
l
step 1598/21- conditions value
bushes additional
works
16 - Function of l Ignition on The warning light Test cable from contact 7 and 9 of the
the ABS -K47- lights up for blue plug on the dash panel insert to
warning light approx. 2 seconds earth.
-K47- and goes out Test cable from contact 19 of the blue
plug on the dash panel insert to contact

16 of the ABS plug binder Current
Flow Diagrams, Electrical Fault Finding
and Fitting Locations
Check dash panel insert, fault in the
dash panel insert: Electrical
System; Rep. gr.90
Functional test: Hand brake/brake fluid level warning light -K14/33-

Test -V.A.G Test covers Test Specified value Measures for deviations from
l
step 1598/21- conditions nominal value
bushes additional

works
17 _ Function of the Brake fluid The warning light Test cable from contact 7 and 9
l
hand brake/brake level O.K. -K14/33- lights up of the blue plug on the dash
fluid level warning l Ignition on for approx. 2 panel insert to earth.
light -K14/33- seconds and goes Test cable from contact 29 of the
out blue plug on the dash panel
insert to the brake fluid level
warning contact -F34-.
Test cable from contact 13 of the
green plug on the dash panel
insert to the handbrake warning
244
switch -F9-.
Test brake fluid level warning
contact -F34- in the cap

binder Current Flow
Diagrams, Electrical Fault
Check dash panel insert, fault in
the dash panel insert:
Electrical System; Rep. gr.90
Replace handbrake warning

switch -F9- Chapter
Functional test: Hydraulic pump -V64-

Test -V.A.G Test covers l Test conditions Specified value Measures for
step 1598/21- additional works deviations from
bushes nominal value
18 _ Function of the l Ignition off
hydraulic Disconnect the plug
pump -V64- connection -T2- of the
hydraulic pump -V64- on the
ABS control unit -J104-.
Connect earth and battery Chapter,

voltage to the plug Hydraulic pump Perform actuator
connection -T2/1- of the starts running diagnosis.
hydraulic pump -T2/2-. without fault (max. Replace ABS
10 secs.)
control unit -J104-
Chapter
Replace hydraulic

Hydraulic pump unit -N55-
does not run Chapter
Switch on measuring range: resistance measurement (200 /20 M)

Test -V.A.G Test l Test conditions Specified Measures for deviations from nominal
step 1598/21- covers additional works value value
bushes
19 11 + 10 Data l Ignition off
BUS l Measuring range 200 set
cables Disconnect the multi-pin
plug connections from the
control units connected to a
data BUS line.
Connect test box -V.A.G

1598/21-.
Check the data BUS cable max. 1.5 Test the wiring according to the

for open circuit. current flow diagram binder
l Measuring range 20 M set
245
Remove fuse.
Check cables for short- Test the wiring according to the
circuit to positive term. or current flow diagram binder
earth. Current Flow Diagrams, Electrical
Electric/electronic components and fitting locations ABS, ABS/EDL Mark 20

1)
All the components marked with are covered by the self-diagnosis.
1- Brake servo unit with master brake cylinder and brake fluid reservoir

1)
2- Hydraulic control unit
t Fitting position: in left of engine compartment
t repairing Chapter
3- Diagnostic connection
t Fitting location: in the storage compartment on the driver's side
4- ABS warning light -K47-
246
t Fitting location: in the dash panel insert, function:
t The ABS warning light comes on:
for about 2 seconds after the ignition is switched on or the engine is started
if a fault is detected (e.g. open circuit to wheel speed sensor)
5- Hand brake/brake fluid level warning light -K14/33-
t The hand brake/brake fluid level warning light comes on:
if hand-brake is applied
if low brake fluid level
for about 2 seconds after ignition is switched on
if the electronic brake pressure distribution fails, i.e. when the ABS warning light comes on
Chapter
6- Parts of ABS system on rear axle
(only disc brake shown in illustration)
t Rear right and left wheel speed sensors -G44- / -G44- 1)
removing and installing Chapter
Installing wheel speed sensor cables Chapter
t Pulse rotor for the wheel speed sensor at the rear on the right and left
check Chapter
removing and installing: The pulse rotor must be changed together with the wheel hub
Chapter and Chapter
7- Brake light switch -F-
t is open in off position
setting up to MY 1999 Chapter, vehicles as of MY 2000 Chapter
removing and installing vehicles up to MY 1999 Chapter, vehicles as of MY 2000
Chapter
t must be tested in the measured value block Chapter
8- Parts of ABS system on front axle
t Front right and left wheel speed sensors -G45- / -G47- 1)
t Pulse rotor for front wheel speed sensor
check Chapter
247
Chapter
Removing and installing the hydraulic control unit and the bracket
Note
Make absolutely sure that no brake fluid gets into the plug connector housing of the control
unit. This may result in the corrosion of the contacts and to system failure. Carefully clean
out the plug connector housing with compressed air if it gets dirty.
t Brake pedal arrester, e.g. -V.A.G 1238/B-
t Caps from the repair set SP no. -1 HO 698 311 A-
t Brake filling and bleeding device e.g. -VAS 5234-
t Extraction bottle (commercially available)
248
the hydraulic pump -V64-, the hydraulic unit -N55- and the ABS control unit -J104- form the
t
hydraulic control unit.
t the hydraulic control unit must be removed and installed as a whole unit
t repairing Chapter
2- Brake line, 14 Nm
t between the master brake cylinder/floating piston circuit and ABS hydraulic unit
t ABS hydraulic unit to front left brake caliper
t ABS hydraulic unit to wheel cylinder/rear right brake caliper
t ABS hydraulic unit to wheel cylinder/rear left brake caliper
t ABS hydraulic unit to front right brake caliper
t between master brake cylinder/push rod piston circuit and hydraulic unit
249
8- Multi-pin connector/ABS control unit
t 25-pin
do not disconnect the plug connector before the self-diagnosis is complete, switch off the
t
ignition before disconnecting the plug connector
10 - Support
11 - Dowel screw, 8 Nm
12 - Cap nut, 25 Nm
Remove the hydraulic control unit
Note
Before disconnecting the battery determine the code of radio sets fitted with anti-theft
t
coding.
t After connecting the battery, perform the following:
on vehicles with radio encoding, carry out the coding,
re-set clock,
initialise power windows on vehicles fitted with power windows BookletOctavia
Disconnect battery.
Note
The following 2 work steps do not apply to the 1.6 ltr./55 kW engine:
Disconnect the plug -1- of the air mass

meter from the air guide pipe of the air
filter.
Unscrew screws -2- at the air filter -3-
and lay it aside.
Remove the relay carrier above the brake
servo unit on diesel engines.
Using an extraction bottle extract as
much brake fluid as possible from the

brake fluid reservoir.
250
Press brake pedal and lock in place with
brake pedal load, e.g. -V.A.G 1238/B-.
Attach the bleeder hose of the bleeding

bottle onto the bleeder screw of the front
left brake caliper and open the bleeder
screw.
Close the bleeder screw once the brake
fluid flowed out.
Disconnect the bleeder hose from the
bleeder screw.
Release the multi-pin connector and
remove it from the hydraulic unit.
Note
Make sure that no brake fluid gets onto the

contacts.
251
In order to collect the brake fluid, position
an absorption fleece under the hydraulic

control unit.
Note
The brake lines around the hydraulic unit

must not be bent.
Protect the brake lines from the master

brake cylinder to the hydraulic unit
against dirt, see -arrows-, with the caps

from the repair set SP no. -1 HO 698 311
A-.
On vehicles with the steering located on

the left, tie up the unscrewed brake lines
with a welding wire as far to the top until
the cable extremities protrude beyond
the brake fluid gauge of the expansion
reservoir -arrows-.
Unscrew the remaining brake lines from
the hydraulic unit.
The connections of the hydraulic lines on

the hydraulic unit must be closed with
the screw plugs -Pos. 2- and -Pos. 3- from
the repair set SP no. -1 HO 698 311 A-.
-Pos. 1- Transport protection for valve
domes (foam material).
252
Unscrew the screws -arrows- on the
bracket for the hydraulic control unit.
Remove the hydraulic control unit .
Install the hydraulic control unit
Note
Only then remove plugs from the

t hydraulic unit when the relevant brake
line is installed.
If the plugs were already removed from

the hydraulic unit before the brake line is
t installed, then brake fluid may escape
and adequate filling and bleeding can no
longer be guaranteed.
Screw hydraulic control unit onto
bracket.
Note
Do not tighten screws. This facilitates the

screwing of the individual brake lines onto
the hydraulic control unit.
Connect the brake lines to the hydraulic
unit and tighten Chapter.
Tighten the hydraulic control unit
-arrows-.
Insert the multi-pin connector on the ABS
control unit and lock.
Connect battery Electrical
System; Rep. gr.27.
Interrogate the fault memory Chapter.
Erasing fault memory Chapter.
Removing and installing bracket
Removing
253
Chapter.
Unscrew nuts -1- and cap nut -3-.
Remove holder -2-.
Install
Installation is carried out in the reverse

order.
Tightening torques:
Nuts to body: 20 Nm
Use new nuts!
Cap nut to body: 25 Nm
Repairing the hydraulic control unit
Disassembly and assembly of the hydraulic control unit is described on an ABS unit. The
work procedure for the other versions of the ABS ITT Mark 20 IE is identical Chapter.
The repair of the hydraulic control unit is carried out by separating the ABS control unit
-J104- from the hydraulic unit -N55- which is connected to the hydraulic pump -V64-. The
defective component is replaced.
Disassembling the hydraulic control unit
Disconnect the plug for the hydraulic pump motor from the control unit.
Unscrew screws -Pfeile- from the control
unit and remove the control unit.
Note
254
During the removal of the control unit -b-
make sure that the valve domes of the
hydraulic unit -a- do not tilt along with the
solenoid coils of the control unit.
Cover the solenoid coils of the control
unit with a non-fluffing cloth.
After separating the hydraulic unit from the

ABS control unit, fit on the transport
protection -1- from the repair set SP no.
-1H0 698 311 A- for the valve domes.
This is a requirement for possible

guarantee claims.
255
ABS hydraulic unit (-N55-) and hydraulic
pump (-V64-) -a-:
Hydraulic unit: The valve block includes

t
the control valves.
Do not separate the hydraulic pump

t
-V64- from the hydraulic unit -N55-.
When changing the hydraulic unit, the

transport protection for valve domes
( Fig., Pos. 1) must be inserted on the
t
old part and the old part must be closed
with the screw plugs ( Fig., Pos. 2 and
3).
ABS control unit (J104) -b-:
Contact assignment Chapter
Test requirements Chapter
Note
There must be no impurities present

t
around the control unit/valve block.
When assembling the control unit and the

hydraulic unit make sure the valve domes
t
of the hydraulic unit do not tilt along with
the solenoid coils of the control unit.
Screw the ABS control unit to the
hydraulic unit. Tightening torque max. 4

Nm (always use the supplied screws).
Mount the plug of the hydraulic pump
motor.
256
Checking/removing and installing parts of the ABS system on the front axle
t Wiring loom repair kit, e.g. Skoda Car Tool Kit koda, Order No.: S 504 500 V
t Solid lubricant paste -G 000 650-
Removing and installing wheel speed sensor
Removing
Raise vehicle.
Separate plug connection of wheel speed
sensor/wheel speed sensor cable -arrow-.
Release screw -2-.
Take the wheel speed sensor -G45- /
-G47- out of the wheel bearing housing.
Install
Clean the inner surface of the hole before

inserting the wheel speed sensor and
coat with a solid lubricant paste -G 000
650-.
Insert the wheel speed sensor in the bore
of the wheel-bearing housing and tighten

the screw to 8 Nm.
Fit together the plug connection of wheel
speed sensor cable/wheel speed sensor.
Actuate steering from left to right up to
the stop and check for free movement of

the wheel speed sensor cable.
Lower the vehicle.
Check pulse rotor or remove and install
Raise vehicle.
Remove wheel.
257
While turning the brake disc, check the
pulse rotor -1- for any dirt or damage.
If the chunking of the pulse rotor is

blocked by dirt, the pulse rotor must be
cleaned.
If the pulse rotor is damaged, the wheel
hub and the pulse rotor must be replaced

Chapter.
Attach the wheel.
Lower the vehicle.
Check axial run-out of pulse rotor
Raise vehicle.
Remove wheel.
Turn the wheel hub and check the

distance between the pulse rotor and the
wheel speed sensor for evenness (axial

run-out tolerance). In this test, the wheel
bearing play must be accounted for.
The axial run-out tolerance of the pulse

l
rotor is 0.3 mm.
If the axial run-out tolerance is not kept,
change the pulse rotor together with the

wheel hub Chapter.
Attach the wheel.
Lower the vehicle.
Removing and installing the wheel speed

sensor cables
Removing
Note
It is prohibited to repair shielded leads of

t
the ABS system.
t Before disconnecting the battery

determine the code of radio sets fitted
258
with anti-theft coding.
After connecting the battery, perform the

t
following:
on vehicles with radio encoding, carry
out the coding,
set clock,
initialise power windows on vehicles

fitted with power windows
BookletOctavia
Disconnect battery.
Note
The following 2 work steps do not apply to

the 1.6 ltr./55 kW engine:
Disconnect the plug of the air mass

meter -1- from the air guide pipe of the
air filter.
and lay it aside.
remove it from the ABS control unit.
259
Slacken the cap of the multi-pin
connector using a screwdriver and
remove it.
Release secondary lock (purple) with a

small screwdriver in the -direction of the
arrow-.
260
Contact assignment of the plug connection
wiring loom/ABS control unit -J104-
Contact Wiring to component ...
19 + 20 Front right wheel speed sensor -G45-
1 +2 Front left wheel speed sensor -G47-
22 + 23 Rear right wheel speed sensor -G44-
5+6 Rear left wheel speed sensor -G46-
Press out the relevant contacts using a

suitable ejection tool from the wiring
loom repair kit.
Release plug connection on wheel speed
sensor and separate plug connector.
Remove defective wheel speed sensor
cable.
Install
Draw in new wheel speed sensor cable.
Connect wheel speed sensor cable to
wheel speed sensor.
261
Clip in wheel speed sensor cable
-arrows-.
Note
When assembling the wheel speed sensor

cable make sure it is not twisted when
installed in the wheelhouse.
Insert contact in the plug housing and

insert the single cable seal with a
suitable plug-in tool from the wiring loom
repair kit up to the stop.
Secure the contacts with the secondary
lock and position the cap of the multi-pin

connector.
System; Rep. gr.27.
Checking/removing and installing parts of the ABS system on the rear axle (disc brake and
drum brake) - front-wheel drive
t Wiring loom repair kit, e.g. Skoda Car Tool Kit koda, Order No.: -S 504 500 V-
262
Remove and install wheel speed sensor (disc brake - front-wheel drive)
Removing
Raise vehicle.
Separate plug connection -1- wheel
Release screw -2-.
Take the wheel speed sensor -G44- /
-G46- out of the axle stud.
Install

coat with a solid lubricant paste -G 000
650-.
Insert the wheel speed sensor in the bore

of the axle stud and tighten the screw -2-
to 8 Nm.
Connect plug connection -1- wheel speed
sensor cable/wheel speed sensor.
Remove and install wheel speed sensor

(drum brake)
Removing and installing the wheel speed

sensor occurs in the same way as for the
disc brake version - front-wheel drive
Chapter.
Plug connection wheel speed sensor

1-
cable/wheel speed sensor
Screw for fixing the wheel speed

2-
sensor.

(disc brake and drum brake)
Note
The figures show only the rear axle with

t
disc brake.
Parts of the ABS system on the rear axle

t with drum brake are analogous to the
version with disc brake.
263
Raise vehicle.
Remove wheel.
Vehicles with disc brakes:
Unscrew screws -A-, remove brake caliper

and tie up laterally with wire or anything
similar.
Brake lines must not be exposed to

tension.
Vehicles with drum brakes:
All vehicles:
Check pulse rotor by turning the brake
disc or the wheel hub
Note
t It is prohibited to repair shielded leads of

264
the ABS system.
Before disconnecting the battery

t determine the code of radio sets fitted
with anti-theft coding.
After connecting the battery, perform the

t
following:
out the coding,
set clock,

BookletOctavia
The figures show only the rear axle with

t
disc brake.
Parts of the ABS system on the rear axle

t with drum brake are analogous to the
version with disc brake.
Disconnect battery.
Raise vehicle.
Remove wheel.
Release plug on wheel speed sensor and
separate plug connection -arrow-.
1- Pulse rotor
2- Wheel speed sensor
3- Wheel speed sensor screw
Remove luggage compartment side trim
panel Body Work; Rep. gr.70.
265
Locate the welded joint on the wheel
speed sensor cable.
Remove the isolating grommet from the
welded joint.
Separate the wheel speed sensor cable in

front of the welded joint using the wire
stripper from the wiring loom repair kit
and remove the defective line piece.
Strip as of 15 mm from the cable
extremity using the wire stripper and turn

the stripped cable halfway.
266
-arrows-.
Note

make sure the wheel speed sensor cable is
not twisted when installed in the
wheelhouse.
Separate the 2-pin plug, if present, on the

new wheel speed sensor cable using the
wire stripper, strip as of 15 mm from the

cable extremity and turn the stripped
cable halfway.
Instead of the welding spot, the wheel

speed sensor cable must be connected
using a suitable crimp connector from the
wiring loom repair kit.
Install luggage compartment side trim
Attach the wheel.
System; Rep. gr.27.
Removing and installing as well as adjusting brake light switch up to model year 1999
t Polycarbamide grease -G 052 152 A2-
Note
The brake light switch must be removed for setting.
Remove footwell covering on driver's side Body Work; Rep. gr.68.
Unplug connector from brake light switch.
267
Remove brake light switch -1- by turning
90 to the left.
To adjust, pull out the plunger -2- of the
brake light switch fully.
Note
Before assembling the brake light switch

grease the contact surface of the brake
pedal tappet with polycarbamide grease -G
052 142 A2-.
Press down brake pedal as far as possible
by hand.
Guide the brake light switch through the
assembly opening and install by turning

90 to the right.
Release brake pedal.
Mount plug on brake light switch.
Install footwell covering on driver's side
Body Work; Rep. gr.68.
Check operation of the brake lights.
Actuate brake pedal all the brake lights

must light up.
Release brake pedal brake lights must go

out.
Removing and installing as well as adjusting brake light switch as of model year 2000

t Polycarbamide grease -G 052 152 A2-
Note
The brake light switch must be removed for setting.

Unplug connector from brake light switch.
268
Remove brake light switch by turning 45 to
the left.
To adjust, pull out the plunger as far as the stop.
The plunger is adjusted automatically when
assembling the brake light switch.
Note
Before assembling the brake light switch grease

the contact surface of the brake pedal tappet with
polycarbamide grease -G052 142 A2-.
Guide the switch through the assembly
opening, press against the pedal and attach by
turning it 45 to the right.
The brake pedal always remains in the off
position in this case (do not depress!).
Insert the plug for the brake light switch.
Inspecting proper operation of the brake light.
After installing the brake light switch, check
whether brake pedal is in the end position (release
position).
Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder
for vehicles with ABS, ABS/EDL Mark 20
Note
t The hydraulic control unit must be removed and installed completely Chapter.
t Repairing Chapter.
t Generally tighten the brake line pipe screws to a tightening torque of 14 Nm.
269
1- Brake servo unit
t check Chapter
t removing and installing - LHD vehicles Chapter
t removing and installing - RHD vehicles Chapter
2- Screw cap
t with integrated brake fluid level warning contact -F34-
3- Brake fluid reservoir
4- Sealing ring
t replace
6- Retaining pin
7- Master brake cylinder
t cannot be repaired, replace completely in the event of faults
t only for vehicles with 74 kW, 92 kW and 110 kW engine

270
9- Heat shield
10 - Cap nut, 25 Nm
11 - 8 Nm
12 - Dampening rubber
13 - Support
15 - Control unit for ABS or ABS/EDL
16 - Hydraulic control unit for ABS or ABS/EDL
17 - Brake line connection
t hydraulic unit to front left brake caliper
t Hydraulic unit to wheel cylinder/rear right brake caliper
t Hydraulic unit to wheel cylinder/rear left brake caliper
t Hydraulic unit to front right brake caliper
21 - Brake line
t Master brake cylinder/push rod piston circuit to hydraulic unit
22 - Brake line
t Master brake cylinder/push rod piston circuit THV to hydraulic unit
271
Self-diagnosis of the ABS/EDL for four-wheel drive vehicles with Haldex coupling
The self-diagnosis for four-wheel drive vehicles with Haldex coupling is almost identical for
vehicles with ABS/EDL.
Note
Only the differences to the normal ABS/EDL system are described in the self-diagnosis.
Characteristic feature of four-wheel drive vehicles with the Haldex coupling
A longitudinal acceleration sender is positioned in the ABS system -G251-.
t Fitting position Chapter
t Fault table Chapter
The longitudinal acceleration sender must be switched off for checking the brake system on a
roller type test stand -G251- Chapter, initiate basic setting, display group number 040.
The reactivation of the longitudinal acceleration sender -G251- is performed by switching the
ignition off and on once.
All four-wheel drive vehicles with Haldex coupling are fitted with the EDL (electronic
differential lock).
Interrogating control unit version
Connect vehicle system tester -V.A.G 1552- Chapter.
Interrogating control unit version page Chapter
Readout on display: 1J0 907 379L ABS/EDL 20 IE CAN

V006 ->
The display shows: Coding 13504
WSC XXXXX
the control unit identification number, e.g. 1J0 907
t
379L
t the system designation, e. g. ABS/EDL 20 IE
t Data BUS: CAN
t the version number, e.g. V006
t the code No. of the control unit, e.g. 13504
the workshop code (WSC) Operating instructions

t
vehicle system tester V.A.G. 1552
Assignment of the control unit electronic catalogue of

original parts

272
273
Fault table for the ABS/EDL of four-wheel drive vehicles with Haldex coupling

-V.A.G 1552-
01279 Open circuit, short-circuit to Read measured value block

t
Longitudinal positive or earth Chapter, display group 006
acceleration sender
-G251- Check wiring and plug connections

electrical fault in the according to the current flow
circuit diagram
Perform electrical test Chapter
The fitting position of the Check the fitting position of the

t longitudinal acceleration longitudinal acceleration sender
sender -G251- is not O.K. -G251-
Longitudinal acceleration Replace longitudinal acceleration

t
sender -G251- defective sender -G251- Chapter
Perform null balance:
Initiate basic setting Chapter,

01279 Read measured value block

Longitudinal Chapter, display group number
acceleration sender 006
-G251-
implausible signal The fitting position of the Check the fitting position of the
t longitudinal acceleration longitudinal acceleration sender
sender -G251- is not O.K. -G251-
Longitudinal acceleration Replace longitudinal acceleration

t
sender -G251- defective sender -G251- Chapter
Perform null balance:
Initiate basic setting Chapter,

01324 Open circuit, short-circuit to Read measured value block

Four-wheel drive control t positive or earth in the data Chapter, display group number
unit -J492- no BUS lines 125
communication
Test the wiring and plug
connections of the data BUS wiring
according to the current flow
diagram
Perform electrical test Chapter
Code ABS/EDL control unit
Code number for ABS/EDL four-wheel drive vehicles with Haldex coupling Chapter.
274
Chapter
Check longitudinal acceleration sender -G251-
Reading measured value block Chapter.
Display group 006
Readout on display:
Enter 006 display group number 006 and confirm with Enter display group number XXX
key Q.
Readout on display: Reading measured value block 6 ->

0.00 m/s2
Display Test conditions Display on V.A.G. 1552
field
1 Longitudinal acceleration sender
Specified value for vehicle at + 0.5m/s2

t
standstill:
t Specified value forwards: Value increases constantly
Value increases constantly with negative

t Specified value backwards:
preceding sign (-)
2 not assigned
3 not assigned
4 not assigned
If the readout differs from the specified values as of:
Perform electrical test page Chapter.
Checking the data BUS cable
Reading measured value block Chapter.

Enter display group number XXX
275
Enter 125 for display group number 125 and confirm
entry with key Q.
Confirm the entry with the key Q.
Readout on display: Reading measured value block 125 ->

Engine 1 four-wheel 1 gearbox 1
Display field Test conditions Display on V.A.G. 1552
Data BUS to engine control unit
1 t Connection available 1
t no connection 0
Data BUS to four-wheel drive control unit
t no connection 0
Data BUS to automatic gearbox control unit
t no connection 0
4 not assigned
If the readout differs from the specified values as of:
Read fault memory of the control units connected to the data BUS
t Engine control unit
t Gearbox control unit (only for automatic gearbox)
t Four-wheel drive control unit.
Test the wiring according to the current flow diagram binder Current Flow Diagrams,
Electrical Fault Finding and Fitting Locations
276
Initiating basic setting
The function 04 Initiate basic setting is extended by two display groups for all four-wheel
drive vehicles with Haldex coupling:
The display group number 040 is required for switching off the longitudinal acceleration
t
sender -G251-, e.g. to check the brake system on a roller type test stand Chapter.
The display group number 069 is required for the null balance of the longitudinal
t
acceleration sender -G251- Chapter.
Note
The reactivation of the longitudinal acceleration sender -G251- is performed by switching the
ignition off and on once.
Initiate basic setting Chapter.
Switch off longitudinal acceleration sender -G251-
Note
No Login procedure is performed for switching off the longitudinal acceleration sender.
Display group number: 040
Readout on display:
Basic setting HELP
Enter 0, 4 and 0 for the display group number 040 and confirm with Enter display group number
key Q. XXX
The ABS warning light flashes
Readout on display:
The longitudinal acceleration sender -G251- is now switched off.
After completing the test, the longitudinal acceleration sender must be reactivated by switching the
ignition off and on once -G251-.
Null balance of the longitudinal acceleration sender -G251-
Note
The Login procedure must be first of all performed for the null balance. To do so first enter the
workshop code in the vehicle system tester -V.A.G 1552-.
Enter 11 for the function Login procedure and confirm HELP
Select function XX
with Q.
Readout on display: Login procedure HELP
Enter code number 40168 and confirm with key Q. Enter code number XXXX
Select function 04 for Initiate basic setting and confirm entry HELP
Select function XX
with key Q.
277
Readout on display:
Basic setting HELP
Enter 069 for the display group number 069 and confirm the entry with Enter display group number
the key Q. XXX

ABS warning light flashes.
Readout on display:
Thus the balance is completed. Balance o.k. 0.3m/s2
The value does not precisely decrease to 0.00 m/s2.
If this readout appears on the display, the login procedure was not Function is unknown or cannot
successfully performed. ->
Repeating the login procedure. be carried out at the moment
If this readout appears on the display, the measured values are not within
the tolerance range allowed for the null balance.
1- Interrogate fault memory (function 02)
2- Erase fault memory (function 05) System in basic setting
69
3- End output (function 06) Balance not possible
4- Switch off ignition. 5.0m/s2
5- Switch on ignition.
6- Perform null balance again.
Press .
Readout on display:
Enter 06, End output. Select function XX
The ABS warning light comes on for approx. 2 seconds.
Electrical test of the ABS/EDL for four-wheel drive vehicles with Haldex coupling
Electrical test ABS/EDL Chapter.
Multi-pin plug connection with contact assignment Chapter.
Additional contact assignment of the multi-

pin plug connection -T25- wiring loom/ABS
control unit -J104-
13 Longitudinal acceleration sender -G251-
278
Overview of test steps (test steps Chapter)
Component to be tested Test steps in the test table Chapter
Actuate the longitudinal acceleration sender -G251- Perform test step 20.
Test table
Test steps 1 to 19 Chapter
The denominations of the bushes of the test box -V.A.G 1598/21- are identical to the
t contact denominations of the ABS control unit -J104- in the current flow diagram binder
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
If the measured values deviate from the nominal values, perform the fault eliminating
t
measures listed in the right part of the table.
Once these values are reached, additionally check the cables for short-circuit to positive
t
and earth.
t Electrical continuity tests with the measuring tool set -V. A. G 1594 A- (bridge structure).
If the measured values only differ slightly from the specified values, clean the bushes and
plugs of the test devices and measuring cables (e.g. with contact spray) and repeat test.
t Before replacing the relevant components test the cables and connections more
specifically for nominal values below 10 , repeat the resistance measurement on the
component.
Test V.A.G Test covers l Test conditions Specifie Measures for deviations
ste 1598/21 d value from nominal value
p bushes additional works
20 _ Cables for l Ignition off

longitudinal
acceleration l Set measuring range 200
sender -G251- Disconnect the electrical plug
connection from the
longitudinal acceleration
sender -G251-
Disconnect the multi-pin

connector -T25a- from the
279
ABS control unit -J104-
1598/21-
Check the cables between max. Test the wiring

the multi-pin connector of the 1.5 according to the
longitudinal acceleration current flow diagram

sender -G251- and the multi- binder Current Flow
pin connector of the ABS Diagrams, Electrical
control unit -J104- for Fault Finding and Fitting
interruption. Locations
l Set measuring range 20 M
Take out the fuse S9
Check cables for short-circuit Test the wiring
to positive or to earth according to the

current flow diagram

binder Current Flow
Diagrams, Electrical
Locations
280
Electric/electronic components and fitting locations (four-wheel drive)
1)
1- Brake master cylinder brake servo unit

1)
t repairing Chapter
281
for about 2 seconds after ignition is switched on and/or engine start
if a fault is detected (e.g. open circuit to wheel speed sensor) Chapter
t The warning light lights up:
Chapter
t Rear right and left wheel speed sensors -G44- / -G46- 1)
check Chapter
Chapter.
t Brake light switch is open in off position
setting up to MY 1999 Chapter, as of MY 2000 Chapter
removing and installing up to MY 1999 Chapter, as of MY 2000 Chapter
t Front right and left wheel speed sensors -G45- / -G47- 1)
t Pulse rotor for the wheel speed sensor at the front on the right and left
check Chapter
Chapter.
9- Longitudinal acceleration sender -G251-1)

282
t Fitting location: on the central pipe to the right, near the right pillar -A-
Removing and installing longitudinal acceleration sender -G251-
Removing
Remove the glove compartment in the dash panel Body Work; Rep. gr.70.
The longitudinal acceleration sender is

located on the central pipe to the right -1-.
Disconnect plug connection -4-.
Unscrew nut -2- (20 Nm) and remove
longitudinal acceleration sender -3-.
Install
order.
Checking/removing and installing parts of the ABS system on the rear axle (disc brake) - four-
wheel drive
t Wiring loom repair kit, e.g. Skoda Car Tool Kit koda, Order No.: S 504 550 V
Removing and installing wheel speed sensor on the rear axle (disc brake) - four-wheel drive
Removing
Raise vehicle.
283
Open the cover -2- of the plug
connection -1-.
Separate plug connection -1- wheel
speed sensor/wheel speed sensor cable.
Release screw -1-.
Pull the wheel speed sensor -G44- / -G46-
from the trailing arm.
Install

coat the wheel speed sensor with a solid
lubricant paste -G 000 650-.
Insert the wheel speed sensor into the
hole of the trailing arm and tighten the

screw -1- to 8 Nm.
Connect the wheel speed sensor to the
wheel speed sensor cable and close the

cover -2- of the plug connection -1-.

(four-wheel drive)
Raise vehicle.
Remove wheel.
284
Unscrew fixing screws -1- from brake
carrier and remove brake carrier with
brake caliper.
Note
Top fixing screw of the brake carrier

covered.
Tie brake caliper to the body.
The brake line must not be exposed to

tension.
While turning the brake disc, check the
pulse rotor for any dirt or damage.
If the chunking of the pulse rotor is

blocked by dirt, the pulse rotor must be
cleaned.
If the pulse rotor is damaged, the wheel
hub and the pulse rotor must be replaced

Chapter.
Install brake caliper:
Attach the wheel.
Lower the vehicle.
Tightening torques:
Wheel bolts 120 Nm
Remove and install the wheel speed sensor cables (four-wheel drive)
Note
t It is prohibited to repair shielded leads of the ABS system.
t
coding.
re-set clock
285
Disconnect battery.
Raise vehicle.
Remove wheel.
Open the cover -2- of the plug
connection -1-.
Disconnect the plug connection -1- from
the wheel speed sensor cable/wheel

speed sensor.
Remove luggage compartment side trim
Locate the welded joint on the wheel
speed sensor cable.
Remove the isolating grommet from the
welded joint.
286
Separate the wheel speed sensor cable in
front of the welded joint using the wire
stripper from the wiring loom repair kit
and remove the defective line piece.
Strip as of 15 mm from the cable
extremity using the wire stripper and turn

the stripped cable halfway.
speed sensor cable/wheel speed sensor

-1- and close cover -2-.
-arrows-.
Note

make sure the wheel speed sensor cable is
not twisted when installed in the
wheelhouse.
Separate the 2-pin plug, if present, on

the new wheel speed sensor cable using
the wire stripper, strip as of 15 mm from

the cable extremity and turn the stripped
cable halfway.
287
Instead of the welding spot, the wheel
speed sensor cable must be connected
using a suitable crimp connector from the
wiring loom repair kit.
Install luggage compartment side trim
Attach the wheel.
System; Rep. gr.27.
288
Antilock braking system ABS/ EDL/ESP Mark 20
Safety precautions, basic information on fault finding and on repairing
The ABS/EDL/ESP is a vehicle security system; system knowledge is required for working
t
on such systems.
Indication of faults by means of warning

t
lights:
ABS (-K47-) -1-
Hand brake/brake fluid level (-K14/331-)
-2-
ESP (-K155-) -3- Chapter.
Certain faults are not detected until after

t a minimum speed of 20 km/h has been
exceeded (conduct a road test).
If the ABS warning light -K47- and the

warning light for the hand brake/brake
fluid level -K14/33- do not light up and if
t in spite of this the brake system is not
fully operational, look for the fault in the
conventional brake system Chapter
and Chapter.
Notes on rectifying sudden faults

Technical Service Handbook binder
t
Current Flow Diagrams, Electrical Fault
Finding and Fitting Locations.
Notes on repair work on ABS/EDL/ESP Mark 20
The same notes which apply for the ABS Mark 20 and the ABS/EDL Mark 20 also apply for the
repair work on the ABS/EDL/ESP Mark 20 Chapter.
t Self-study programme no. 26 vehicle safety - new technical information
t Self-study programme no. 28 electronic stability program, basis, construction, function
289
Distinguishing features of the ABS/EDL ITT Mark 20 IE and the ABS/EDL/ESP ITT Mark 20 IE
The ABS prevents the wheels from locking during a brake application initiated by the driver.
The electronic differential lock, EDL, is a starting-off aid. A supporting torque is created for the differential
by electronically controlling the braking of the driven wheel which is slipping. The engine power is thus
available for the gripping wheel with the better adhesion. This also applies when reversing.
A description of the structure and function of the ABS and the EDL can be found in self-study programme
No. 26.
The electronic stability program -ESP- recognises critical driving conditions and stabilises the vehicle by
individual wheel braking and by intervention in the engine control. This occurs independently of a brake or
accelerator pedal activation.
The ESP is active over the entire speed range. If the ESP is in regulating mode, the ESP warning lights flash
three times per second.
The description of the structure and function of the ESP can be found in self-study programme No. 28.
The brake system is split diagonally. Brake servo assistance is provided pneumatically by the vacuum brake
servo unit.
Vehicles fitted with ABS/EDL/ESP ITT Mark 20 IE do not have a mechanical brake pressure regulator.
Specifically matched software in the control unit, the electronic brake pressure distribution, EBD, regulates
the brake pressure on the rear axle.
The hydraulic pump -V64-, the hydraulic unit -N55- and the control unit -J104- form the hydraulic control
unit. A repair is only possible in the removed condition.
New control units supplied through the Parts Division are not coded. They must be coded after installation.
ABS/EDL/ESP ITT Mark 20 IE
Note
Inlying electrical plug connection

t
between hydraulic unit and control unit.
12 valve domes: The protective sleeves

for the valves are visible if the control
t
unit is separated from the hydraulic unit
Chapter.
t -1- 47-pin control unit.
Control unit identification. The control

unit version is shown on the display of
t the vehicle system tester -V.A.G 1552-.
Select function 01 interrogate control
unit version Chapter.
Overview of selectable functions

t
Chapter.
290
Fitting position ABS/EDL/ESP ITT Mark 20 IE

2- Hydraulic unit
3-
unit

2- Hydraulic unit
3-
unit
291
Self-diagnosis of the ABS/EDL/TCS/ESP Mark 20
Description of the function
As the control units are interlinked over a data BUS line, always start fault finding by interrogating the
contents of the fault memories of all the control units fitted to the vehicle.
The interrogation of the fault memory is performed with the key function 00 Automatic test sequence.
When doing so check whether a possibly stored fault might affect the ABS system.
Self-diagnosis relates to the electrical/electronic part of the ABS, i. e. faults are detected only over the
electrical connection to the control unit (e.g. open circuit of a wheel speed sensor).
The 47-pin ABS control unit -J104- together with the hydraulic unit forms a compact unit. The unit is
located in the left of the engine compartment. The control unit is equipped with a fault memory. The
connection for self-diagnosis is located in the storage compartment on the driver's side.
The control unit detects faults during the operation of the vehicle and stores them in a permanent memory,
whose information is retained even if the battery voltage is disconnected.
Faults which occur sporadically (isolated) are likewise detected and stored. If this fault which affects the
data BUS system no longer occurs during 15 vehicle starts and driving-off procedures or 50 vehicle starts
and driving-off procedures and if the fault does no longer reappear with other faults, it is erased from the
fault memory (fault delete counter) with the exception of the fault control unit defective.
After the ignition is switched on and/or the engine is started, the ABS warning lights -K47-, the red warning
light for the hand brake/brake fluid level -K14/33- and the ESP warning light -K155- flash for approx. 2
seconds.
During this period a test sequence (self-check) is performed in the control unit with the following functions:
t Test of supply voltage, min. 10.0 V
t Test of control unit including valve coils.
t Check of control unit coding
t Static test of the wheel speed sensor (without speed signal)
After a start-up, should it appear that the speed signal is not O.K as of approx. 20 km/h, the ABS warning
t
light lights up again -K47-.
Initiate self-diagnosis at the start of fault finding and retrieve the stored information using the vehicle
system tester -V.A.G 1552- or the fault read-out scan tool -V.A.G 1551-.
Note
The following description only relates to the vehicle system tester -V.A.G 1552- using the current
t
program card.
The use of the fault reader -V.A.G 1551- with integrated printer is similar. A minor deviation on the
t
display read-out is possible.
t To end the self-diagnosis or to switch to another address word select function 06 End output.
t Identify the faults displayed by referring to the fault table and subsequently carry out the fault elimination.
Indication of faults by means of warning lights -K47-, -K14/33- and -K155-
292
Arrangement of warning lights
Pos. Denomination
1 ABS warning light -K47-
2 Hand brake/brake fluid level warning light -K14/33-
3 ESP warning light -K155-
WARNING
Once the ABS warning light -K47- and the hand brake/brake fluid level warning light -K14/33-
have lit up, then the rear wheels can already lock when braking lightly.
Overview
Meaning ABS warning Hand brake/brake fluid ESP warning

light -K47- level warning light light -K155-
-K14/33-
Ignition on (if the systems are OK, the

lights up lights up lights up
lights go out after approx. 3 s)
ESP failure or ESP deactivated by means does not

does not light up lights up
of button; ABS, EDL and EBD are active light up
System O.K. does not does not

does not light up
light up light up
ESP intervention does not

does not light up flashes
light up
ABS/EDL/ESP failure; EBD remains active

lights up does not light up lights up
(e.g. a wheel speed sensor is defective)
293
ABS/EDL/ESP/EBD failure; (e.g. a wheel
lights up lights up lights up
speed sensor is defective)
Brake fluid level too low; all systems does not does not
lights up
O.K. light up light up
Warning light -K47-
If the ABS warning light (-K47-) -1- does

not go out after the ignition is switched
t on and after completion of the test
sequence, the causes of the fault may
be:
-a- the supply voltage is less than 10 V
-b- an ABS fault is present
The antilock braking system is switched off

if an ABS fault -b- is present. The EBD
function (Electronic Brake pressure
Distribution) is furthermore active while the
conventional brake system remains fully
operational. Interrogate the fault memory
Chapter.
-c- a sporadic fault existed on a wheel

speed sensor after the last vehicle start
In case of a wheel speed sensor fault -c-,

the ABS warning light goes out
automatically -K47- after restarting the
reached.
-d- The line of the ABS control unit -J104-

for operating the ABS warning light -K47- in
the dash panel insert -J218- is interrupted
binder Current Flow Diagrams, Electrical
-e- Dash panel insert defective
294
Warning light -K47- and -K14/33-
If the ABS warning light goes out (-K47-)

-1- but the warning light for the hand
brake/brake fluid level (-K14/33-) -2-
t
remains lit and 3 warning tones are
audible, the following can be the causes
of the fault:
-a- the brake fluid level is too low
-b- the hand-brake is still applied
-c- the switch -F9- for the warning light

-K14/33- is defective or incorrectly adjusted
-d- a fault in the operation of the hand

brake/brake fluid level warning light
-K14/33- binder Current Flow Diagrams,
Electrical Fault Finding and Fitting
Locations.
If the ABS warning light (-K47-) -1- and

the hand brake/brake fluid level warning
t light (-K14/33-) -2- light up, then the ABS
system and the EBD (Electronic Brake
pressure Distribution) have failed.

light (-K14/33-) -2- light up and 3 warning
t
tones are audible, then the ABS and the
EBD (Electronic Brake pressure
Distribution) have failed.
Note
The warning light for the hand brake/brake

fluid level (-K14/33-) -2- only lights up after
exceeding a speed of 10 km/h once or an
engine speed of 2000 rpm.
WARNING
Once the ABS warning light -K47- and the

hand brake/brake fluid level warning light
-K14/33- have lit up, then the rear wheels
can already lock when braking lightly.
295
Warning light -K155-
If the ESP warning light (-K155-) -3- does

be:
There is a fault which exclusively effects

the ESP. The ABS/EDL and EBD safety
systems on the vehicle remain fully
functional. Interrogate the fault memory
Chapter.
-a- Short circuit to positive in ESP button

-E256-
-b- Short circuit to earth in the operation of

the ESP warning light -K155-
-c- the line for operating the ESP warning

light -K155- is interrupted binder
Current Flow Diagrams, Electrical Fault
-d- the ESP system was switched off using

the ESP button -E256-
If the ESP warning light lights up -K155- for

approx. 100 milliseconds after switching on
the ignition, a coding without ESP control
was entered.
If the ESP warning light -K155- flashes

while driving, the ESP system is operating
in regulating mode.
Warning light -K47-, -K14/33- and -K155-

t light (-K14/33-) -2- flash and the ESP
warning light (-K155-) -3- remains lit, the
control unit is not yet coded.
296
Vehicle fitted with ABS/EDL/ESP - EDL does not operate
t Diagnostic cable -V.A.G 1551/3- or -V.A.G 1551/3 A-
Complaint: Vehicle EDL system does not operate
When dealing with this complaint a possible fault cause may be that the brake light switch is
incorrectly set or is not operating Chapter, set display group number 003 and brake light
switch, Chapter.
297
Electrical test of the ABS/EDL/ESP ITT Mark 20 IE
t Measuring tool set -V.A.G 1594/A-
t Test box -V.A.G 1598/A-
t Adapter -V.A.G 1598/33-
The test steps Chapter apply only to vehicles with ABS/EDL/ESP,
for which the self-diagnosis does not indicate the fault source. In this case the full electric
t
inspection must be carried out.
for which the self-diagnosis gives a direct indication of the fault source. Then only perform
t
the test steps recommended in the fault table (targeted approach).
Test conditions
Before starting the test switch off the ignition and electrical consumers (headlights,
l
lighting, blowers...).
Fuses S13, S15, S162, S163 must be O.K. binder Current Flow Diagrams, Electrical Fault
l
Finding and Fitting Locations To check, remove fuses from the fuse holder.
Note
The following 2 work steps do not apply to the 1.6 ltr./55 kW engine.
Remove air filter

air filter.
Screw out screws -2- at the air filter -3-
and lay it aside.
Connect test box -V.A.G1598 A- with

adapter -V.A.G 1598/33-
298
Disconnect the multi-pin connector -1- in
the -direction of arrow a- and remove it

from the ABS control unit -arrow b-.
Connect the test box -V.A.G 1598 A- with
adapter -V.A.G 1598/33--1- to the plug of

the wiring loom -2-.
Note
The specified values are specific to the

handheld multimeter -V.A.G 1526 A- and do
not necessarily apply for other measuring
tools.
Note
All unlisted contacts are not yet assigned and must under no circumstances be connected to
other components!
299
-T16a- (diagnostic connection) with the
vehicle system tester -V.A.G 1552-
Contact 4 -Earth (terminal 31)
Contact 16 -Positive (terminal 30) for S12
Contact 7 --K- cable via cable connection - diagnosis - to ABS control unit -J10- 4, contact 39

-T47a- wiring loom/ABS control unit -J104-
Conta
Wiring to component ...
ct
1 Solenoid coil for brake pressure -N247-
2 Earth point on the left below the battery
5 Control unit with display unit for radio and navigation (only for navigation system)
300
9 Lateral acceleration sender -G200- (earth lead)
10 Brake pressure sender 2 -G214-
11 Yaw rate sender -G202- (earth lead)
13 Brake detection switch of the ESP -F83-1)
14 not assigned
16 Voltage supply of battery + (via S162)
17 Solenoid coil for brake pressure -N247-
Data BUS cable binder Current Flow Diagrams, Electrical Fault Finding and Fitting
19
Locations
Data BUS cable binder Current Flow Diagrams, Electrical Fault Finding and Fitting
20
Locations
21 not assigned
23 Brake light switch -F-
24 TCS/ESP button -E256- / voltage supply relay for warning light -K155-
25 Lateral acceleration sender -G200- (voltage line)
27 Yaw rate sender -G202- (voltage line)
30 not assigned
31 Brake light suppression relay -J508-
301
35 Control unit with display unit for radio and navigation (only for navigation system)
38 not assigned
39 Plug connection -T16a/7-, -K- cable
40 Lateral acceleration sender -G200- (signal line)
42 Yaw rate sender -G202- (signal line)
44 Voltage supply terminal 15 via S 13
45 not assigned
47 Voltage supply battery + (via S163)
1)
Brake detection switch ESP -F83- is identical to release switch of the solenoid coil for
brake pressure -F84-.
Voltage supply of the ABS hydraulic pump -V64- - Perform test step 1
Voltage supply of the valves in the hydraulic unit - Perform test step 2
Voltage supply of the control unit -J104- - Perform test step 3
Function of the brake light switch -F- - Perform test step 4
Brake light suppression relay -J508- - Perform test step 5
Jumper - Perform test step 6
Resistance of the front right speed sensor -G45- - Perform test step 7
Resistance of the front left speed sensor -G47- - Perform test step 8
Resistance of the rear right speed sensor -G44- - Perform test step 9
Resistance of the rear left speed sensor -G46- - Perform test step 10
Voltage signal of the front right speed sensor -G45- - Perform test step 11
302
Voltage signal of the front left speed sensor -G47- - Perform test step 12
Voltage signal of the rear right speed sensor -G44- - Perform test step 13
Voltage signal of the rear left speed sensor -G46- - Perform test step 14
Function of the ABS warning light -K47- - Perform test step 15
Function of the hand brake/brake fluid level warning light -K14/33- - Perform test step 16
Function of the ESP warning light -K155- - Perform test step 17
Function of the ESP button -E256- - Perform test step 18
Actuation of the steering angle sender -G85- - Perform test step 19
Actuation of the lateral acceleration sender -G200- - Perform test step 20
Actuation of the yaw rate sender -G202- - Perform test step 21
Actuation of the brake pressure sender -1--G201- - Perform test step 22
Actuation of the solenoid coil for brake pressure -N247- - Perform test step 24
Actuation of the brake detection switch -F83-1) - Perform test step 25
Test of the data BUS cable - Perform test step 26
Voltage supply for -V.A.G 1551-, plug connection -T16a- - Perform test step 27
Resistance of the -K- cable for the self-diagnosis, plug connection -T16a- - Perform test step 28
1)
The brake detection switch -F83- is identical to the release switch of the solenoid coil for
brake pressure -F84-.
303
Test table
Notes for the test table
The denominations of the bushes of the test box -V.A.G 1598 A- with adapter -V.A.G
1598/33- are identical to the contact denominations of the control unit -J104- in the current
t
flow diagram binder Current Flow Diagrams, Electrical Fault Finding and Fitting
Locations
If the measured values deviate from the specified values, perform the fault eliminating
t measures listed in the right part of the table binder Current Flow Diagrams, Electrical
plugs of the test devices and measuring cables (e.g. with contact spray -G 000 700 04-) and
t repeat test. Before replacing the relevant components test the cables and connections
more specifically for nominal values below 10 , repeat the resistance measurement on the
component.
Test steps 1 - 20
Test steps 21 - 28 Chapter
Test -V.A.G Test covers Test Specifie Measures for deviations from
step 1598 A- l condition d value nominal value
bushes s
additional
works
1 15 + 47 Voltage supply of the ABS Ignition 10.0- Test wiring of contact

l
hydraulic pump -V64- off 14.5V -T47a/47- via fuse S163 to
(terminal 30) at the ABS battery positive.
control unit -J104-
Test wiring of contact
-T47a/15- to earth binder

Current Flow Diagrams,
Electrical Fault Finding and
Fitting Locations
2 46 + 16 Voltage supply for the Ignition 10.0- Test wiring of contact

l
valves in the ABS off 14.5V -T47a/16- via fuse -S162- to
hydraulic unit -N55- battery positive.
(terminal 30) at the ABS
control unit -J104- Test wiring of contact
304
Fitting Locations
3 44 + 46 Voltage supply of the ABS Ignition 10.0- Test wiring of contact

l
control unit -J104- on 14.5V -T47a/44- via fuse S13 and
(terminal 15) ignition starter switch.


Fitting Locations
Switch on measuring range:

voltage measurement (20 V =) in test step 4, resistance measurement (200 )/(20 M) in
test step 4a
Test -V.A.G Test l Test conditions Specifie Measures for deviations from nominal
step 1598 A- covers d value value
bushes additional works
4 23 + 46 Brake l Ignition off 0,0-0,5 If necessary set brake light switch

light V Chapter.
switch Brake pedal not
l
-F- actuated Replace brake light switch

Chapter.
Actuate brake pedal 10.0- Check contact 1 of the brake light

14.5V switch -F- to fuse S13.
4a Brake Measuring range Test wiring for open circuit.

l
light 200 set
switch Repair the wiring according to the
-F- Pull out the multi-pin current flow diagram binder
connector -T47a- from Current Flow Diagrams, Electrical
the ABS control unit Fault Finding and Fitting Locations
-J104-
Pull out the multi-pin

connector from the max.1.5
brake light/brake
pedal switch
Test wiring for open

circuit

23 (control unit) to
contact 1 (brake light
switch)
l Measuring range
305
20 M set
Remove fuse S13
Check cables for

short-circuit to
positive or to earth
Test -V.A.G Test covers Test Specifie Measures for deviations from nominal
l
step 1598 A- conditions d value value
bushes
additional

works
5 23 + 46 Brake light l Ignition on 10.0- Brake light suppression relay -J508-.

suppression 14.5V
relay -J508- Brake
l pedal
actuated
31 + 15 Bridge 0,0-0,5 Test the wiring according to the current

bushes 31 V flow diagram for open circuit and short-

and 15 circuit binder Current Flow Diagrams,
Locations
Switch on measuring range: resistance measurement (200 )/(20 M)
Test -V.A.G 1598 Test l Test conditions Specified Measures for deviations
step A- bushes covers value from nominal value
additional works
6 8 + 18 Table of l Ignition off max. 1.5 Test wiring of contact 8

codes to contact 18 for open
Detach multi-pin connector circuit

-T47a-
Connect test box -V.A.G 1598

A- with adapter -V.A.G
1598/33-
Test wiring for open circuit
306
l
bushes
additional
works
7 3+4 Resistance of the Ignition 1,0 ... Separate plug connection on speed
l
front right speed off 1.3 k sensor.
sensor -G45-
Test wiring according to the current

flow diagram.
Throughout the test, move cables

binder Current Flow Diagrams,
Locations
Replace wheel speed sensor -G45-

Chapter
8 33 + 34 Resistance of the Ignition 1,0 ... Separate plug connection on speed

l
front left speed off 1.3 k sensor.
sensor -G47-

flow diagram.

Locations

Chapter
9 7+6 Resistance of the Ignition 1,0 ... Separate plug connection on speed
l
rear right speed off 1.3 k sensor.
sensor -G44-

flow diagram.

Locations

Chapter
307
10 37 + 36 Resistance of the Ignition 1,0 ... Separate plug connection on speed
l
rear left speed off 1.3 k sensor.
sensor -G46-

flow diagram.

Locations
Replace speed sensor -G46-

Chapter.
Switch on measuring range: voltage measurement (20 V ~)
step 1598 A- value nominal value
bushes additional

works
11 3 + 4 Voltage signal l Vehicle raised Alternating Check the installation of the

of the front voltage min. wheel speed sensor and the
right speed l Ignition off 65 mV pulse rotor.
sensor -G45- Turn front right Check wheel speed sensor -G45-
wheel by to ensure it is correctly
approx. 1 turn
connected and read measured
per sec. value block Chapter, display
group number 001

left speed l Ignition off 65 mV pulse rotor.
sensor -G47- Turn front left Check wheel speed sensor -G47-
approx. 1 turn
group number 001

of the rear voltage min. wheel speed sensor and the
sensor -G44- Turn rear right Check wheel speed sensor -G44-
approx. 1 turn connected and read measured
308
group number 001

sensor -G46- Turn rear left Check wheel speed sensor -G46-
approx. 1 turn
group number 001
Test -V.A.G Test l Test conditions Specified Measures for deviations from
ste 1598 covers value nominal value
p A- additional works
bushes
15 - Function The fault memory The warning If the ABS warning light does not
of the ABS was interrogated and light -K47- light up for approx. 2 seconds:
warning there is no fault in lights up for
l Test wiring of contact
light -K47- the fault memory of approx. 2
the ABS control unit seconds and -T47a/22- (control unit) to
-J104- goes out contact -T32a/19- (dash panel

again insert) for short-circuit to
l Ignition off earth. Binder Current Flow
The multi-pin Finding and Fitting Locations
connector is inserted
l on the ABS control Check dash panel insert, fault

unit -J104- and in the dash panel insert
locked Electrical System; Rep. gr.90
Switch on ignition
Test -V.A.G Test covers Test Specified Measures for deviations from
l
ste 1598 conditions value nominal value
p A-
bushes additional

works
16 - Function of the Brake fluid

l
hand level is O.K.
brake/brake
l Ignition off
309
fluid level
warning light
-K14/33- Multi-pin
connector
inserted on
l
control unit
-J104- and
locked
Switch on

ignition
Functional test: ESP warning light -K155-
Test -V.A.G Test l Test conditions Specified Measures for deviations from nominal
ste 1598 covers value value
p A- additional

bushes works
17 - Function l Ignition off The warning Test wiring of contact -T47a/22-

of the ESP light -K155- (control unit) via the voltage supply
Multi-pin
warning lights up for relay -J535- to contact -T32b/14-
light connector approx. 2 (dash panel insert) for open circuit
-K155- inserted on seconds and and short-circuit to positive.
l
control unit goes out
-J104- and If the warning light -K155- remains lit:
locked
Test wiring of contact -T47a/22-
Switch on (control unit) via the voltage supply

ignition relay -J535- to contact -T32b/14-

(dash panel insert) for short-circuit
to earth binder Current Flow
Diagrams, Electrical Fault Finding
and Fitting Locations
Check dash panel insert, fault in the

dash panel insert.
Test the ESP button -E256-

Electrical System ; Rep. gr.90
Test voltage supply relay for

warning light -K155- binder
Functional test: Warning light for TCS/ESP button -E256- in test step 18; voltage supply (20
310
V=) in test step 18a
Test -V.A.G Test covers l Test conditions Specified value Measures for deviations from
ste 1598 A- nominal value
18 - Function of l Ignition off The warning

the light -K155-
TCS/ESP The function of lights up for
button the TCS/ESP approx. 2
-E256- l warning light seconds and
-K155- was tested goes out again
with test step 17
The multi-pin
connector is
l inserted on the
ABS control unit
-J104- and locked
Switch on

ignition
Operate TCS/ESP Warning light Perform test step 18a

button -K155- comes
on
Operate TCS/ESP Warning light

button once -K155- goes out
again
18a 15 + Function of Switch off Test wiring of contact

24 the ignition -T47a/15- (control unit) to
TCS/ESP earth.
button Pull out the multi-
-E256- pin connector Test wiring of contact
from the ABS -T47a/24- (control unit) to
control unit -J104- contact -T4f/2- (TCS/ESP
button) for open circuit or
Connect test box short-circuit to positive or to
-V.A.G 1598 A- earth.
with adapter
-V.A.G 1598/33-
Switch on

ignition
Button -E256- not 3,5-5,0 V Test wiring of contact

pressed and -T47a/24- (control unit) to
warning light contact -T32b/14- (dash panel
-K155- lights up insert) for open circuit and
short-circuit to positive or to
earth.
Button -E256- 8,0 - 14,5V Test voltage supply of contact

311
held pressed and -T4f/1- (TCS/ESP button) via
warning light fuse S13 for open circuit
-K155- lights up binder Current Flow
Replace TCS/ESP button


test step 19a
Test -V.A.G Test covers l Test conditions Specifie Measures for deviations from
ste 1598 A- d value nominal value
19 - Earth connection l Ignition off Test wiring of contact -T6w/4-

and voltage (steering angle sender) to
supply of the Pull out the multi- fuse S15 for open circuit.
steering angle pin connector
sender -G85- -T47a- from the ABS Repair the wiring according to
control unit -J104- the current flow diagram

binder Current Flow
Disconnect the plug Diagrams, Electrical Fault
connection from the Finding and Fitting Locations
steering angle
sender
Test the voltage

supply of the

steering angle
sender at the plug
connection -T6w-
Test wiring between 10.0-

contact -T6w/4- and 14.5V
contact -T6w/1-
l Ignition on Test wiring of contact -T6w/5-

(steering angle sender) to
Test wiring between 10.0- fuse S13 for open circuit

contact -T6w/5- and 14.5V binder Current Flow
contact -T6w/1- Diagrams, Electrical Fault
19a - Cables for Measuring range

l
steering angle 200 set
sender -G85-
Connect test box
-V.A.G 1598 A- with
312
adapter -V.A.G
1598/33-
check the following

wiring for open
circuit:
Wiring of contact max. Test wiring for open circuit.

-T6w/3- (steering 1.5
Repair the wiring according to
angle sender) with
contact -T47a/19- the current flow diagram

(control unit) binder Current Flow
Wiring of contact Finding and Fitting Locations
-T6w/2- (steering

angle sender) with
contact -T47a/20-
(control unit).
Wiring of contact

T6w/1 to earth
Measuring range
l
20 M set
Remove fuse S13
Check cables for

short-circuit to
20 - Cables for l Ignition off

lateral
acceleration Measuring range 200
l
sender -G200- set
Remove fuse S13

connector -T47a- from
the ABS control unit
-J104-
Connect test box

-V.A.G 1598 A- with
adapter -V.A.G
313
1598/33-
Disconnect the plug

connection -T3n- from
Check the following max. Test wiring for open circuit.
line connections for an 1.5

open circuit: Repair the wiring according
to the current flow diagram
Wiring of contact binder Current Flow
-T3n/1- (lateral Diagrams, Electrical Fault
acceleration sender) Finding and Fitting

with contact -T47a/40- Locations
(control unit)
Wiring of contact
-T3n/2- (lateral
acceleration sender)
with contact -T47a/9-
(control unit)
Wiring of contact max.

-T3n/3- (lateral 1.5
(control unit)
Measuring range
l
20 M set
Remove fuse S13

Check cables for short-
circuit to positive or to
earth
314
Test steps 21 - 28
Test V.A.G Test l Test conditions Specifie Measures for deviations from
step 1598 A covers d value nominal value

yaw rate
sender Measuring range 200
l
-G202- set

connector -T47a- from
the ABS control unit
-J104-.
Connect test box

-V.A.G 1598 A- with
adapter -V.A.G
1598/33-
Disconnect the plug

connection -T3m- from
the yaw rate sender
-G202-
Check the following Test wiring for open circuit.

line connections for an
open circuit: Repair the wiring according to
the current flow diagram

Wiring of contact max. binder Current Flow
-T3m/1- (yaw rate 1.5 Diagrams, Electrical Fault
sender) with contact Finding and Fitting Locations
-T47a/42- (control unit)
Wiring of contact
-T3m/2- (yaw rate
sender) with contact
Wiring of contact
-T3m/3- (yaw rate
Measuring range
l
20 M set
Remove fuse S13


earth
315

brake
pressure Measuring range 200
l
sender 1 set
-G201- Pull out the multi-pin


1598 A- with adapter
-V.A.G 1598/33-
Disconnect the plug

connection -T30- from the
brake pressure sender
-G201-
Check the following line Test wiring for open circuit.

connections for an open
circuit: max. Repair the wiring according
1.5 to the current flow diagram
Wiring of contact -T30/1- binder Current Flow
(brake pressure sender) Diagrams, Electrical Fault

via plug connection Finding and Fitting
-T14c/1- with contact Locations
Wiring of contact -T30/2-

(brake pressure sender)

via plug connection
-T14c/2- with contact
Wiring of contact -T30/3-


via plug connection
Measuring range 20 M
l
set

316
earth

brake
l
sender 2 set
-G214- Pull out the multi-pin


1598 A- with adapter
-V.A.G 1598/33-
Disconnect the plug

connection -T3p- from the
brake pressure sender
-G201-
Check the following line Test wiring for open circuit.

circuit:
Wiring of contact -T3p/1- max. Repair the wiring according

(brake pressure sender 2) 1.5 to the current flow diagram

via plug connection binder Current Flow
-T14c/12- with contact Diagrams, Electrical Fault
-T47a/26- (control unit) Finding and Fitting
Locations
Wiring of contact -T3p/2-
(brake pressure sender 2)

via plug connection
Wiring of contact -T3p/3-


via plug connection
317
l
set
Remove fuse S13

earth

solenoid coil
for brake l Measuring range 200 set
pressure Pull out the multi-pin
-N247-

1598 A- with adapter -V.A.G
1598/33-
Disconnect plug connection

T6x at brake servo unit
Check the following line

circuit:
Wiring of contact -T6x/4-

(solenoid coil for brake
pressure -N247-) via plug
connection -T14c/7- with
contact -T47a/17- (ABS
control unit)
Wiring of contact -T6x/3- Test wiring for open

(solenoid coil for brake max. circuit.
pressure -N247-) via plug 1.5
connection -T14c/8- with Repair the wiring according
contact -T47a/17- (ABS to the current flow diagram
control unit -J104-). binder Current Flow
Finding and Fitting
Locations
318

Remove fuse S13

earth
l Measuring range 200 set The brake servo unit must

1.0 ... be replaced if the
Disconnect multi-pin 2.0 k specified value is not

connector T14c reached Chapter.
Check contacts -7- and -8-
in the plug connection
-T14c- to the solenoid coil
for brake pressure -N247-
Test -V.A.G Test l Test conditions Specifie Measures for deviations from
ste 1598 A- covers d value nominal value
25 - Brake l Ignition off

detection
switch l Measuring range 200 set
-F83- Pull out the multi-pin

Connect test box -V.A.G 1598

1598/33-
Disconnect plug connection

-T6x- at brake servo unit

circuit:
Wiring of contact -T6x/1-

(brake detection switch
-F83-) via plug connection
-T47a/13- (ABS control unit
-J104-)
Wiring of contact -T6x/2- Test wiring for open circuit.

319
-F83-) via plug connection Repair the wiring according
-T14c/6- with contact to the current flow diagram
-T47a/29- (ABS control unit binder Current Flow
-J104-) Diagrams, Electrical Fault
Finding and Fitting
Wiring of contact -T6x/5- Locations
-F83-) via plug connection
-T47a/327- (ABS control unit
-J104-).

Remove fuse S13
Check cables for short-circuit

to positive or to earth
ste 1598 A- covers d value nominal value
26 19+20 Data l Ignition off

BUS
cables l Measuring range 200 set
Disconnect the multi-pin plug
connections from the control
units connected to a data BUS
line (connection in the dash
panel wiring loom -A122- and
-A121-)
Connect test box -V.A.G 1598 A-

with adapter -V.A.G 1598/33-

connections for an open circuit:
to the steering angle sender
to the engine control unit
to the automatic gearbox

control unit 1)
Wiring of contact -T47a/19- max. Test wiring for open circuit.

(control unit) via connection 1.5
A121 to contact -T6w/3- Repair the wiring according
320
(steering angle sender -G85-) to the current flow diagram
binder Current Flow
Continue via connection A121 to Diagrams, Electrical Fault

the connected control units Finding and Fitting
Wiring of contact -T47a/20- Locations
(control unit) via connection
A122 to contact -T6w/2-
(steering angle sender -G85-).
Continue via connection A122 to

the connected control units
according to current flow
diagram

Remove fuse S13
Check cables for short-circuit to

1)
Only on vehicles with automatic gearbox
Test -V.A.G Test covers l Test conditions Specifie Measures for deviations
ste 1598 A- d value from nominal value
27 - Voltage supply for l Ignition on Test wiring of -T16a/4- to

vehicle system earth.
tester -V.A.G Connect the handheld 10.0-
1552-, plug multimeter, e.g. -V.A.G 14.5V Test wiring of -T16a/1- via

connection -T16a- 1526 A-, with the -S5-.
measuring tool set
Repair the wiring
-V.A.G 1594 A- to -T16a-
1)
according to the current
flow diagram binder
Test wiring between Current Flow Diagrams,
Electrical Fault Finding
contact -T16a/4- and
contact -T16a/1- and Fitting Locations
1)
Contact assignment of the plug connection for the voltage supply and the self-diagnosis
with the vehicle system tester -V.A.G 1552- Chapter
321
step 1598 A- d value nominal value
28 - -K- cable for the l Ignition off

self-diagnosis,
plug connection Measuring range max. Test wiring of contact -T16a/7-
l
T16a 200 set 1.5 to contact -T47a/39-
Remove fuse S13 Repair the wiring according to

the current flow diagram
Pull out the multi-
binder Current Flow
pin connector Diagrams, Electrical Fault

-T47a- from the Finding and Fitting Locations
ABS control unit
-J104-
Connect test box

-V.A.G 1598 A- with
adapter -V.A.G
1598/33-
Test wiring
between contact
-T16a/7- and
contact -T47a/39-
Measuring range Repair the wiring according to

l
20 M set the current flow diagram

binder Current Flow
Remove fuse S13 Diagrams, Electrical Fault
Check cables for Finding and Fitting Locations

short-circuit to
322
Electric/electronic components and fitting locations ABS/EDL/ESP Mark 20
The brake servo unit includes the following components:
Release switch of the solenoid coil for brake pressure -F84-; This switch is identical to the
t
brake detection switch ESP -F83-.
t The brake detection switch ESP-F83- is tested by self-diagnosis
t Solenoid coil for brake pressure in the brake servo unit -N247-
The solenoid coil for brake pressure in the brake servo unit -N247- is tested by self-
t
diagnosis
2- Brake pressure sender 1 -G201-
t are checked by self-diagnosis
t The brake pressure sender 1 and the brake pressure sender 2 are equal parts
t The fitting location for the brake pressure sender 1 can also be the Pos. 3 for the brake
323
pressure sender 2
3- Brake pressure sender 2 -G214-
t are checked by self-diagnosis
t The brake pressure sender 2 and the brake pressure sender 1 are equal parts
The fitting location for the brake pressure sender 2 can also be the Pos. 2 for the brake
t
pressure sender 1
4- Cable duct
t Brake detection switch -F83-
t Solenoid coil for brake pressure
5- Plug connection -T14c-
t Brake detection switch -F83-
t Solenoid coil for brake pressure in the brake servo unit -N247-
t Brake pressure sender -1--G201-
t Brake pressure sender -2--G214-
6- Lateral acceleration sender -G200-
t Fitting location: next to the steering column under the dash panel
t is checked by self-diagnosis
7- Yaw rate sender -G202-
8- Steering angle sender -G85-
Fitting location: on the steering column between the steering wheel and the steering
t
column switch
9- ESP warning light -K155-
t Fitting location: in the dash panel insert
t function Chapter
10 - Hand brake/brake fluid level warning light -K14/33-
t function Chapter
324
11 - ABS warning light
t function Chapter
12 - Parts of ABS system on rear axle
t Rear right and rear left wheel speed sensors -G44/G46-
check Chapter
Chapter and Chapter
13 - Parts of ABS system on front axle
t Front right and front left wheel speed sensors -G45/G47- 1)
check Chapter
Chapter
14 - Voltage supply relay for warning light -K155--J535-
t Fitting location: additional relay carrier, space 7
15 - Diagnostic connection
16 - Brake light switch -F-
17 - Control unit for ABS/EDL/ESP -J104-
325
t Fitting location: at the hydraulic unit in left of engine compartment
t Check the multi-pin plug connection to the control unit Chapter
Do not disconnect the multi-pin plug connection before the self-diagnosis is complete.
t
switch off the ignition before disconnecting the plug connector.
18 - Hydraulic unit for ABS/EDL/ESP -N55-
t Fitting position: left of engine compartment
the hydraulic unit -N55- consists of the hydraulic pump -V64- and the valve block with the
t
inlet and exhaust valves
when changing the hydraulic unit, absolutely close the old part with a plug from the
t
mounting part kit; SP no. Electronic Catalogue of Original Parts
Remove and install hydraulic control unit (hydraulic unit -N55- with control unit -J104-)
t
Chapter
t Do not separate the hydraulic pump -V64- from the valve block.
t Repairing the hydraulic control unit Chapter
Removing and installing the hydraulic control unit ABS/EDL/ESP and the bracket
Note
t Diagnostic cable -V.A.G 1551/3- or -V.A.G 1551/3A-
t Brake pedal load, e.g. -V.A.G 1238/B-, or -V.A.G 1869/2-
Mounting part kit, SP no. Electronic Catalogue of Original Parts The mounting part kit
t
consists of a plug and a protective cap
326
1- Multi-pin connector/ABS control unit
t 47-pin
do not disconnect the plug connector before the self-diagnosis is complete, switch off the
t
ignition before disconnecting the plug connector
the hydraulic pump -V64-, the ABS hydraulic unit -N55- and the ABS control unit -J104- form
t
the hydraulic control unit
t the hydraulic control unit must be removed and installed completely Chapter.
t repairing Chapter
t between master brake cylinder/floating piston circuit and hydraulic unit
t ABS hydraulic unit to front left brake caliper
t ABS hydraulic unit to rear right brake caliper
t ABS hydraulic unit to wheel cylinder/rear left brake caliper
327
t ABS hydraulic unit to front right brake caliper
10 - Support
12 - Cap nut, 25 Nm
Note
t
coding.
set clock,
Disconnect battery.
Note
328
filter.
and lay it aside.

brake pedal load, e.g. -V.A.G 1238/B- or

-V.A.G 1869/2-.

screw.
fluid flowed out.
bleeder screw.
Release the multi-pin connector -1- (-
arrow a-) and disconnect it from the

hydraulic control unit (-arrow b-).
Note

contacts.
329
In order to collect the brake fluid,
position an absorption fleece under the

hydraulic control unit -1-.
Note
The brake lines around the hydraulic unit

must not be bent.
Screw out the brake lines from the

master brake cylinder to the hydraulic
unit, see -arrows-, and protect them

against dirt with the screw plugs from the
mounting part kit.

reservoir.
the hydraulic unit.

the plugs from the mounting part kit.
-Pos. 1- Protective cap for valve domes

(foam material).
The plugs -Pos. 2 and 3- as well as the

protective cap -Pos. 1- are part of the
scope of delivery of the mounting part kit
SP no. for mounting part kit Electronic
Catalogue of Original Parts
330
Unscrew the screws -arrows- on the
Note
The third fixing screw for the hydraulic

control unit is covered by the hydraulic
pump -V64-.
Note
Only then remove plugs from the

t hydraulic unit when the relevant brake
line is installed.
If the plugs were already removed from

the hydraulic unit before the brake line is
t installed, then brake fluid may escape
and adequate filling and bleeding can no
longer be guaranteed.
bracket.
Note

Connect the brake lines to the hydraulic
unit and tighten Chapter.
331
Tighten the hydraulic control unit
-arrows-.
Note
The third fixing screw for the hydraulic

control unit is covered by the hydraulic
pump -V64-.
System; Rep. gr.27.
If the control unit was replaced while

repairing the hydraulic control unit -J104-,
a null balance must be performed for the
following components:
t Steering angle sender -G85-
t Lateral acceleration sender -G200-
t Brake pressure sender 1 -G201-
Initiate basic setting and perform null
balance Chapter.
Erasing fault memory Chapter
Removing and installing bracket
Removing
Chapter.
332
Unscrew nuts -1- and cap nut -3-.
Remove holder -2-.
Install

order.
Tightening torques:
Nuts to body 20 Nm
t Use new screws!
Cap nut to body 25 Nm
Repairing the hydraulic control unit ABS/EDL/ESP
Mounting part kit, SP no. Electronic Catalogue of Original Parts. The mounting part kit
t
consists of a plug and a protective cap
Disassembling the hydraulic control unit
333
The repair of the hydraulic control unit is
carried out by separating the ABS control
unit (-J104-) -1- from the hydraulic unit (-
N55-) -2-, which is connected to the
hydraulic pump (-V64-) -3-.
Only the ABS control unit (-J104-) -1- or the

hydraulic unit (-N55-) -2- with the hydraulic
pump (-V64-) -3- can be replaced. The
hydraulic unit and the hydraulic pump
must not be separated from each other
and therefore cannot be replaced
individually.
Screw out the screws from the control
unit -arrows- and remove the ABS control

unit from the hydraulic unit.
Note
When removing the ABS control unit -b-,

make sure the valve domes -1- of the
hydraulic unit -a- do not tilt along with the
solenoid coils -2- of the ABS control unit
-b-.
Cover the solenoid coils of the control
unit with a non-fluffing cloth.
334
After separating the hydraulic unit from
the ABS control unit, fit the protective
cap -1- onto the valve domes of the
hydraulic unit.
Note
The protective cap -1- and the plugs -2-

t and -3- are component parts of the
mounting part kit.
The plugs and the protective cap of the

newly installed hydraulic units can be
t
used instead of thoses from the mounting
part kit.
ABS hydraulic unit (-N55-) and hydraulic

pump (-V64-) -a-:
Hydraulic unit: The valve block includes

t
the control valves.
Do not separate the hydraulic pump

t
-V64- from the hydraulic unit -N55-.
When changing the hydraulic unit, the

protective cap for valve domes
( Anchor, Pos. 1) must be inserted on
t the old part and the old part must be
closed with the screw plugs ( Anchor,
Pos. 2 and 3). This is a requirement for
possible guarantee claims.
1 - Valve domes of the hydraulic unit
2- Solenoid coils of the control unit
ABS control unit (-J104-) -b-:
If the ABS control unit was replaced while

repairing the hydraulic control unit -J104-,
a null balance must be performed for the
following components:
t Steering angle sender -G85-
335
t Lateral acceleration sender -G200-
Contact assignment Chapter,
Test requirements Chapter
Assembling the hydraulic control unit
Note
There must be no impurities present

t
around the control unit/valve block.
When assembling the control unit and

the hydraulic unit make sure the valve
t domes of the hydraulic unit do not tilt
along with the solenoid coils of the
control unit.
Screw the ABS control unit to the
hydraulic unit. Tightening torque: 4 Nm

(always use the supplied screws).
t Wiring loom repair kit, e.g. Skoda Car Tool Kit koda, Order No.: -S 504 500 V-
Removing and installing wheel speed sensor
Chapter
Chapter
Check axial run-out of pulse rotor
Chapter
Removing and installing the wheel speed sensor cables
Note
336
t It is prohibited to repair shielded leads of the ABS system.
t
coding.
set clock,
Removing
Disconnect battery.
Note

air filter.
and lay it aside.
Release the multi-pin connector -1- (-
arrow a-) and disconnect it from the ABS

control unit -arrow b-.
Unlock the cap -1- of the multi-pin

337
connector -2- using a screwdriver and
remove it.

arrow-.

3+4 Front right wheel speed sensor -G45-
33 + 34 Front left wheel speed sensor -G47-
6+7 Rear right wheel speed sensor -G44-
36 + 37 Rear left wheel speed sensor -G46-
338
Press out the relevant contacts using a suitable ejection tool from the wiring loom repair
kit.
Release plug connection on wheel speed sensor and separate plug connector.
Remove defective wheel speed sensor cable.
Install
Connect wheel speed sensor cable to wheel speed sensor.
-arrows-.
Note

339
Insert contact in the plug housing and
insert the single cable seal with a
suitable plug-in tool from the wiring loom
repair kit up to the stop.
lock (purple).
Lock the secondary lock (purple) with a

arrow-.
Position the cap on the multi-pin
connector.
control unit -J104- and lock.
System; Rep. gr.27.
340
Removing and installing parts of the ESP system
The description of the structure and function of the ESP can be found in self-study
programme No. 28.
Remove and install yaw rate sender -G202- and lateral acceleration sender -G200-
t
Chapter
t Remove and install steering angle sender -G85- Chapter
Remove and install yaw rate sender -G202- and lateral acceleration sender -G200-
The removal and installation procedure of the yaw rate sender -G202- and the lateral
acceleration sender -G200- is the same except for the direct replacement of the sender to be
removed.
Note
t
coding.
set clock,
Removing
Disconnect battery.
341
Remove the bottom part of the dash
panel -1- Body Work; Rep. gr.70.
Remove the bottom part of the steering

column trim panel -2- Body Work; Rep.
gr.70.
The yaw rate sender (-G202-) -1- and the

lateral acceleration sender (-G200-) -2- are
fixed with a common bracket -3- at the
mounting bracket for the steering column
-a-.
Note
Due to the common bracket, the senders

cannot be removed separately. After
removing the bracket, the yaw rate sender
-G202- and the lateral acceleration sender
-G200- can be replaced separately.
Disconnect the plugs -arrows- from the
yaw rate sender -G202- and from the

lateral acceleration sender -G200-.
Unscrew screw -5- and remove bracket
-3- with yaw rate sender -G202- and

lateral acceleration sender -G200-.
Replace yaw rate sender -G202-
342
Unscrew the nuts -a- from the yaw rate
sender (-G202-) -1-.
Remove the yaw rate sender (-G202-) -1-
from the bracket -3-.
-2- Lateral acceleration sender -G200-
Insert the new yaw rate sender (-G202-)

-1- into the bracket -3- and align it
straight.
Screw on nuts -a- and tighten.
Replace lateral acceleration sender -G200-
Lever off the holder -2- from the lateral
acceleration sender (-G200-) -1- using a

screwdriver.
Remove the lateral acceleration sender (-
G200-) -1- from the bracket -4-.
-3- Yaw rate sender -G202-
Insert the new lateral acceleration sender
(-G200-) -1- into the bracket -3-.
-4- Yaw rate sender -G202-
Note
The inclined side -arrow- of the lateral

acceleration sender (-G200-) -1- must point
in the direction of the holder -2-.
Push the holder -2- over the lateral

acceleration sender (-G200-) -1- and
lock.
Install
343
Mount the bracket -3- with the lateral
acceleration sender (-G200-) -2- and the
yaw rate sender (-G202-) -1- on the

mounting bracket -4- for the steering
column -a-.
Insert and tighten screw -5-.
Fit on plug for yaw rate sender (-G202-)
-1- and plug for lateral acceleration

sender (-G200-) -2- (arrows).
Install the bottom part of the steering

column trim panel Body Work; Rep.
gr.70.
Install bottom part of dash panel Body
Work; Rep. gr.70.
System; Rep. gr.27.
Tightening torques:
Yaw rate sender (-G202-) 9 Nm
Bracket at mounting bracket for steering column 20 Nm
Removing and installing steering angle sender -G85-
Note
t
coding.
set clock,
initialise power windows on vehicles fitted with power windows BookletOctavia.
Removing
344
Disconnect battery.
Put the front wheels in straight ahead position.
Remove steering wheel Body Work; Rep. gr.69.
Unscrew screws -1-, -2-, -3- and -4-.
Remove the handle for the steering

wheel adjuster as well as the top and
bottom part of the steering column trim
panel.
- Check whether the front wheels are in the

straight-ahead position.
If necessary, fit on the steering wheel
and put the front wheels in a straight

ahead position.
Remove steering wheel.
The steering angle sender -G85- is fitted

together with the coil spring -2- in the
housing -1-.
Note
The following two work steps must only be

performed when reinstalling at a later
stage the same housing with a coil spring.
345
Position the steering angle sender in the
centre position:
A yellow dot must be visible in the window

-1-.
The markings -arrows- must be flush.
Make sure this position is maintained.
Secure the coil spring -2- against
unintentional turning by covering it with

adhesive tape -1-.
-3- Housing
Disconnect plugs -1- and -2-
346
Carefully release catch hooks -arrows-
and remove housing -1- with steering

angle sender -G85- and coil spring.
Install
Slide housing -1- with steering angle

sender -G85- and coil spring onto the
steering column and lock into position
with steering column switch -arrows-.
Connect both plug connections.
Note
After removing the transport protection or

the adhesive tape do not turn the coil
spring, only the positioning of the steering
angle sender -G85- in centre position is
allowed.
Removing transport protection or
adhesive tape.
centre position:

-1-.
Markings -arrows- must be flush with each

other.
Make sure this correct position is

maintained.
Remove the top and bottom part of the
steering column trim panel as well as the

handle for the steering wheel adjuster.
Install steering wheel Body work; Rep.
gr.69.
System; Rep. gr.27.
Perform the basic setting of the steering
angle sender -G85- Chapter.
347
Removing and installing as well as setting the brake light switch
up to MY 1999 Chapter
as of MY 2000 Chapter
for vehicles with ABS/EDL/ESP Mark 20
Note
The complete master brake cylinder and brake servo unit can be replaced independently of
t
one another.
348
1- Brake servo unit
t check Chapter
3- Gasket
t for brake servo unit
4- Bellows
t pay attention to correct position, risk of suction noises
5- Holder
t is attached to the edge of the brake servo unit
t serves for the support of the plug - Pos. 15
6- Screw cap
8- Sealing ring
t replace
9- Retaining bracket
t for fixing the wiring loom - Pos. 16
10 - Plugs
t moisten with brake fluid and press in expansion reservoir
11 - Retaining pin
t fit through the master brake cylinder
12 - Master brake cylinder
13 - Brake pressure sender -1--G201-
t in the floating piston circuit
t in the push rod piston circuit
349
15 - Connector
t Connection wiring loom dash panel/engine compartment
16 - Wiring loom
18 - Heat shield
t only for vehicles fitted with a 110 kW engine
19 - Cap nut, 25 Nm
21 - Dampening rubber
22 - Support
24 - Control unit for ABS/EDL/ESP
25 - Hydraulic unit for ABS/EDL/ESP
26 - Brake line connection, 14 Nm
30 - Brake line, 14 Nm
32 - Plugs
33 - Vacuum hose
t with non-return valve
t insert in brake servo unit.
350
351
Antilock braking system (ABS) MK60
Safety precautions, basic information on fault finding and on repairing ABS and ABS/TCS/EDL
MK 60
Antilock braking system (ABS) ITT Mark 20 IE Chapter.
Notes on repair work on ABS and ABS/TCS/EDL MK 60
Antilock braking system (ABS) ITT Mark 20 IE Chapter.
t ABS Self-study programme
Chapter.
ABS and ABS/TCS/EDL
The ABS and ABS/TCS/EDL do not differ on the exterior.
t Control unit identification
The control unit version appears in the display of -V.A.G 1552-. Select function 01 interrogate
control unit version Chapter. electronic catalogue of original parts
Fitting position ABS or ABS/TCS/EDL MK 60
Chapter
Electric/electronic components and fitting locations ABS/EDL/TCS Mark 60

1)
352

1)
t repairing Chapter
for about 2 seconds after the ignition is switched on or the engine is started
if a fault is detected (e.g. open circuit to wheel speed sensor) Chapter
t The hand brake/brake fluid level warning light comes on:
353
Chapter
t Rear right and rear left wheel speed sensors -G44/G46- 1)
check Chapter
Chapter and Chapter
check Chapter
Chapter
Removing and installing the hydraulic control unit and the bracket
Note
354
t Brake pedal load, e.g. -V.A.G 1238/B-
the hydraulic pump -V64-, the hydraulic unit -N55- and the ABS control unit -J104- form the
t
t the hydraulic control unit must be removed and installed completely Chapter
t the connections of the brake lines are embedded on the hydraulic control unit
t repairing Chapter
2- Support
355
3- Nut, 20 Nm
4- 8 Nm
7- Multi-pin connector/control unit
t 47-pin
Do not disconnect the plug connection before the self-diagnosis is complete. switch off the
t
ignition before disconnecting the plug connector.
t between master brake cylinder/floating piston circuit and hydraulic unit
Note
Before disconnecting the battery determine the code of the radio sets fitted with anti-theft
t
coding.
t After connecting the battery, check the vehicle equipment:
set clock,
Disconnect battery.
Note
356
filter.
and lay it aside.

brake pedal load, e.g. -V.A.G 1238/B-.

screw.
fluid flowed out.
bleeder screw.
remove it from the control unit -arrows-.
Note

contacts.
In order to collect the brake fluid,
position an absorption fleece under the

Note
Do not bend the brake lines around the

357
Screw out the brake lines from the
master brake cylinder to the hydraulic
unit, see -arrows-, and protect them

against dirt with the caps from the repair
set.

reservoir -arrows-.
the hydraulic unit.

the screw plugs from the repair set.
Unclip the cable for clutch control -arrow
A-.
Unscrew the screws -arrows B- on the
Note
Only then remove plugs from the hydraulic

unit when the relevant brake line is
installed.
bracket.
Note

Connect the brake line to the hydraulic
control unit and tighten Chapter.
358
Tighten the hydraulic control unit -arrows
B-.
Clip on the cable for clutch control
-arrow A-.
Insert the multi-plug connector on the
System; Rep. gr.27.
Repairing the hydraulic control unit
Note
The components of the hydraulic control unit are fitted together and connected by 2
t
screws.
Before removing the Torx screws, secure the hydraulic pump against unintentional
t
separation from the hydraulic pump with adhesive tape.
t The hydraulic pump and the hydraulic unit constitute a replacement part.
WARNING
The hydraulic pump must not be separated from the hydraulic unit.
359
1- Torx screws, 8 Nm
2- Hydraulic unit
The hydraulic unit consists of: -a- Hydraulic pump for ABS or ABS/TCS/EDL -V64--b- Hydraulic
unit for ABS or ABS/TCS/EDL -N55-
t the valve block includes the control valves
t after separating them from the control unit, fit on the transport protection for valve domes
3- Control unit for ABS or ABS/TCS/EDL -J104-
when removing them from the hydraulic unit, the valve domes of the hydraulic unit must
t
not tilt along with the solenoid coils of the control unit
t Cover the solenoid coils with a non-fluffing cloth
t Contact assignment Chapter
t Test requirements Chapter
Assembling the hydraulic control unit
Note
t There must be no impurities present around the control unit/valve block.
360
When assembling the control unit and the hydraulic unit make sure the valve domes of the
t
hydraulic unit do not tilt along with the solenoid coils of the control unit.
Chapter.
Removing and installing the wheel speed sensor cables
Removing
Note
t It is prohibited to repair shielded ABS cables.
t
coding.
t After connecting the battery, check the vehicle equipment:
set clock,
initialise power windows on vehicles fitted with power windows.
Disconnect battery.
Note

air filter.
and lay it aside.
361
remove it from the control unit -arrows-.
Unclip the cap of the multi-pin connector

using a screwdriver -arrows- and remove
it.

arrow-.
362
wiring loom/ABS control unit -J104-
Contact Wiring to component
33 + 34 Front right wheel speed sensor -G45-
45 + 46 Front left wheel speed sensor -G47-
42 + 43 Rear right wheel speed sensor -G44-
36 + 37 Rear left wheel speed sensor -G46-
Press out the relevant contacts using a suitable ejection tool from the wiring loom repair
kit.
Release plug connection on wheel speed sensor and separate plug connector.
Remove defective wheel speed sensor cable.
Install
Connect wheel speed sensor cable to wheel speed sensor.
363
-arrows-.
Note

Insert the contact in the plug housing and

insert the single wire seal with a suitable
plug-in tool from the wiring loom repair
kit up to the stop.
lock and position the cap of the multi-pin

connector.
System; Rep. gr.27.
Chapter.
ABS/EDL/TCS Mark 60
Note
364
1- Brake servo unit
t check Chapter
2- Sealing ring
t replace
3- Screw cap
5- Plugs
6- Retaining pin
t replace
9- Brake line
t Master brake cylinder/push rod piston circuit THV to hydraulic unit

365
10 - Brake line
t only fitted on certain models
t replace
12 - Heat shield
t only fitted on certain models
13 - Hydraulic control unit
t repairing Chapter
t Connections of brake lines Chapter
14 - Support
t with rubber insulation
15 - Insert flange nut, 20 Nm
16 - 8 Nm
Electrical test ABS/EDL/ TCS Mark 60
t Measuring tool set -V.A.G 1594 A-
t Test box -V.A.G 1598 A-
t Adapter e.g. -V.A.G 1598/36-
The test steps as of page Anchor apply only for vehicles with ABS/EDL/TCS
Vehicles for which the final control diagnosis does not indicate the fault source. In this case
t
the full electric inspection must be carried out.
Vehicles for which the final control diagnosis does give a direct indication of the fault
t source. Then only perform the test steps recommended in the fault table (targeted
approach).
An overview of all the test steps of the electrical test can be found on the page Chapter.
Test requirements
366
Before starting the test switch off the ignition and electrical consumers (headlights,
t
lighting, blowers etc.).
The fuses must be OK (to check, remove fuses from the fuse holder) binder Current
t
Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Remove the protective housing for relays from the cable duct.
Disconnect the plug -1- from the control

unit -J104--arrow a- and remove it -arrow
b-.
Connect the test box -V.A.G 1598/36- with

adapter -V.A.G 1598/36--1- to the multi-
pin plug connection of the control unit
-J104--2-.
Note
The specified values are specific to the

-V.A.G 1526 A- and do not necessarily apply
for other measuring tools.
Multi-pin plug connections with contact assignment for ABS, ABS/EDL/TCS
Contact assignment of plug connection -T16a- of diagnostic coupling
Chapter
367
-T47a- wiring loom/ABS control unit -J104-.
Note
are not used.
45 - Front left wheel speed sensor -G47-
368
47 - Earth
Voltage supply for the hydraulic pump -V64- to the control unit -J104- - Perform test step
1
Voltage supply of the valves in the hydraulic unit -N55- to the control unit - Perform test step
-J104- 2
Voltage supply (ignition starter switch) to the control unit -J104- - Perform test step
3
Function of the brake light switch -F- - Perform test step

4
Resistance of the front right speed sensor -G45- - Perform test step
5
Resistance of the front left speed sensor -G47- - Perform test step
6
Resistance of the rear right speed sensor -G44- - Perform test step
7
Resistance of the rear left speed sensor -G46- - Perform test step
8
Voltage signal of the front right speed sensor -G45- - Perform test step
9
Voltage signal of the front left speed sensor -G47- - Perform test step
10
Voltage signal of the rear right speed sensor -G44- - Perform test step
11
Voltage signal of the rear left speed sensor -G46- - Perform test step
12
Function of the ABS warning light -K47- - Perform test step

13
Function of the hand brake/brake fluid level warning light -K14/33- - Perform test step
14
Function of the TCS button -E132- - Perform test step

15
Test of the data BUS cable - Perform test step
369
16
Voltage supply for -V.A.G 1551-, plug connection -T16a- - Perform test step
17
Resistance of the K cable for the self-diagnosis, plug connection -T16a- - Perform test step
18
Jumper - Perform test step

19
Test table
Notes for the test table
The denominations of the bushes of the adapters -V.A.G 1598/36- are identical to the
t contact denominations of the ABS control unit -J104- in the current flow diagram binder
Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Fault Finding and Fitting Locations.
plugs of the test devices and measuring cables (with contact spray -G 000 700 04-) and
more specifically for nominal values below 10 , repeat the resistance measurement on
the component.
Test -V.A.G Test covers Test Specified Measures for deviations from
l
step 1598 A- conditions value nominal value
bushes
additional
works
1 1 +47 Voltage supply for the l Ignition off 10.0 - Test the wiring according to the
hydraulic pump -V64- 14,5V current flow diagram binder

(terminal 30) to the Current Flow Diagrams,
control unit -J104- Electrical Fault Finding and
Fitting Locations.
2 32 + 16 Voltage supply of the l Ignition off 10.0 - Test the wiring according to the
valves in the hydraulic 14,5V current flow diagram binder

unit -N55- (terminal Current Flow Diagrams,
30) to the control unit Electrical Fault Finding and
-J104- Fitting Locations.
3 4 + 47 Voltage supply l Ignition on

370
(terminal 15) of the
control unit -J104-
4 47 + 41 Function of the brake l Ignition off Test brake light switch -F- and
light switch -F- 0.0 - 0.5 read measured value block
Brake V Chapter; display group
l pedal not number 003.
actuated
Test the wiring according to the
current flow diagram binder

Fitting Locations.
Brake approx. Check brake light switch -F-

pedal battery Chapter.
actuated voltage
bushes additional

works
5 33 + 34 Resistance of l Ignition off 1.0...1.3 k Check wiring according to

the front right current flow diagram.
speed sensor
-G45- Throughout the test, do not
move cables binder Current
Flow Diagrams, Electrical Fault
If the lines are not found to be

faulty:

Chapter.
6 45 + 46 Resistance of t Ignition off 1.0...1.3 k Check wiring according to

the front left current flow diagram.
speed sensor

faulty:
371
Chapter.

the rear right current flow diagram.
speed sensor

faulty:

Chapter.

the rear left current flow diagram.
speed sensor

faulty:

Chapter.
9 33 + 34 Voltage signal l Vehicle raised Check the installation of the

of the front wheel speed sensor -G45- and
right speed l Ignition off the rotor.
sensor -G45-
Turn front right Alternating Check wheel speed sensor
wheel by voltage min. -G45- to ensure it is correctly

approx. 1 turn 65 mV connected and read measured
group number 001.

of the front left wheel speed sensor -G47- and
speed sensor l Ignition off the rotor.
-G47-
Turn rear left Alternating Check wheel speed sensor

approx. 1 turn 190mV connected and read measured
group number 001

of the rear wheel speed sensor -G44- and
right speed l Ignition off the rotor.
372
sensor -G44- Turn rear right Alternating Check wheel speed sensor

group number 001.

of the rear left wheel speed sensor -G46- and
speed sensor l Ignition off the rotor.
-G46-
Turn rear left Alternating Check wheel speed sensor

group number 001.
l
step 1598 A- conditions nominal value
bushes
additional
works
13 - Function of IgnitionThe warning light Test the wiring according to the

l
the ABS off -K47- lights up for current flow diagram binder

warning approx. 2 seconds Current Flow Diagrams, Electrical
light -K47- Switch on and goes out Fault Finding and Fitting
ignition Locations.
Fault in the dash panel insert.

Test -V.A.G Test covers Test Specified Measures for deviations

l
step 1598 A- conditions value from nominal value
bushes
additional

works
14 - Function of the hand Handbrake Warning light Fault in the dash panel
l
brake/brake fluid level not applied -K14/33- insert Electrical
warning light -K14/33- System; Rep. gr.90
Brake fluid
l
level is O.K.
373
l Ignition on
Apply Warning light Fault in the dash panel

handbrake -K14/33- insert Electrical
lights up System; Rep. gr.90
Functional test: Function of the TCS button -E132-
l
step 1598 A- conditions nominal value
bushes
additional

works
15 - Function of l Ignition on The warning light

the TCS -K86- lights up for
button approx. 2 seconds
-E132- and goes out
TCS button TCS warning light Test the wiring according to the

-E132- -K86- lights up current flow diagram binder

operated Current Flow Diagrams,
Fitting Locations.
Operate TCS TCS warning light Replace TCS button -E132-

button -E132- -K86- goes out Body Work; Rep. gr.70
once again
step 1598 A- covers d value nominal value
16 11 Data l Ignition off

or BUS
15 cables l Measuring range 200
set

control units connected to
a data BUS line:
Connect -V.A.G 1598 A-

with adapter -V.A.G
374
1598/36-
Check the data BUS cable max. Test the wiring according to the

for open circuit 1.5 current flow diagram binder

Locations.
Set measuring range

20 M
Check cables for short- Test the wiring according to the

circuit to positive or to current flow diagram binder

earth Current Flow Diagrams,
Locations.
17 - Voltage supply l Ignition off

for -V.A.G
1552-, plug Connect the handheld 10.0 - Test the wiring according
connection multimeter -V.A.G 1526- 14,5V to the current flow diagram

-T16a- 1) with the measuring tool binder Current Flow
set -V.A.G 1594- to the Diagrams, Electrical Fault
plug connection -T16a-1) Finding and Fitting
Locations.
1)
Contact assignment of the diagnostic connector Chapter.
ste 1598 d value from nominal value
bushes
18 - Resistance of l Ignition off

the K cable for
-V.A.G 1552-, Disconnect the multi-pin plug
connection from the control
375
plug unit -J104-
connection
-T16a-1) Connect -V.A.G 1598 A- with

Connect the handheld max. Test the wiring

multimeter -V.A.G 1526- with 1.5 according to the
the measuring tool set -V.A.G current flow diagram

1594- to the contacts -T16a/7- binder Current Flow
1)
and -T47a/2-2) of the multi- Diagrams, Electrical
pin plug connections from the Fault Finding and
control unit -J104-. Fitting Locations.
1)
Contact assignment of the diagnostic connector Chapter.
2)
Contact assignment of the control unit plug Chapter.
l
bushes
additional
works
19 14 + 38 Jumper for Ignition 0.0 - 1.0 Test the wiring according to the current
t
ABS/EDL/TCS off flow diagram binder Current Flow
Fitting Locations.
376
Antilock braking system ABS/ EDL/TCS/ESP Mark 60
Safety precautions, basic information on fault finding and on repairing
Chapter
Notes on repair work on ABS/EDL/TCS/ESP Mark 60
Chapter
t Current Flow Diagrams, Electrical Fault Finding and Fitting Locations.
Electric/electronic components and fitting locations ABS/EDL/TCS/ESP Mark 60 MY 02

1)
377
1- Brake servo unit
t with master brake cylinder and brake fluid reservoir
t Remove and install brake servo unit Chapter
2- Brake pressure sender -1--G201-1)
3- Lateral acceleration sender -G200-1)
4- Yaw rate sender -G202-1)
5- Steering angle sender -G85-1)
t
column switch
378
t function Chapter
t function Chapter
t function Chapter
check Chapter
Chapter and Chapter
10 - Brake vacuum pump -V192-1)
t only on vehicles with automatic gearbox in combination with EU-4 engines
t Fitting location: on the left of the assembly carrier
is checked by self-diagnosis in the engine control unit Engine, Fuel Injection and Ignition
t
System; Rep. gr.01
12 - Brake light switch -F-1)
adjust Chapter
remove by turning 90 to the left Chapter
install by turning 90 to the right Chapter
t must be tested in the measured value block 003 Chapter
379
Do not disconnect the multi-pin plug connection before the self-diagnosis is complete.
t
switch off the ignition before disconnecting the plug connector.
14 - Hydraulic unit for ABS/EDL/ESP -N55-1)
t
when changing, absolutely close the old part with a plug from the mounting part kit; SP no.
t
Electronic Catalogue of Original Parts
Remove and install hydraulic control unit (hydraulic unit -N55- with control unit -J104-
t
Chapter
check Chapter
Chapter
16 - Longitudinal acceleration sender -G251-1)
t Fitting location: on the central pipe to the right, near the right pillar -A-
Electric/electronic components and fitting locations ABS/EDL/TCS/ESP Mark 60 MY 02

1)
380
1- Brake servo unit
t with master brake cylinder and brake fluid reservoir
t Remove and install brake servo unit Chapter
2- Brake pressure sender -1--G201-1)
3- Sensor unit for ESP -G419-
t RHD 4x4 vehicles without -G251-
4- Steering angle sender -G85-1)
t
column switch
381
t function Chapter
t function Chapter
t function Chapter
check Chapter
Chapter and Chapter
9- Brake vacuum pump -V192-1)
only on vehicles with automatic gearbox in combination with the limit values of exhaust gas
t
according to EU-4
t Fitting location: on the left of the assembly carrier
is checked by self-diagnosis in the engine control unit Engine, Fuel Injection and Ignition
t
System; Rep. gr.01
11 - Brake light switch -F-1)
adjust Chapter
remove by turning 90 to the left Chapter
install by turning 90 to the right Chapter
t check: measured value block 003 Chapter
382
t switch off the ignition before disconnecting the plug connection
13 - Hydraulic unit for ABS/EDL/ESP -N55-1)
t
when changing, absolutely close the old part with a plug from the mounting part kit; SP no.
t
Remove and install hydraulic control unit (hydraulic unit -N55- with control unit -J104-
t
Chapter
check Chapter
Chapter
15 - Longitudinal acceleration sender -G251-1)
t Fitting location:
only RHD 4x4 vehicles on the central pipe to the right, near right pillar -A-
383
Distinguishing features ABS/EDL/TCS Mark 60 and ABS/EDL/TCS/ ESP Mark 60
Chapter
Fitting position ABS/EDL/TCS/ESP Mark 60

2- Hydraulic unit
3-
unit

2- Hydraulic unit
3-
unit
384
Self-diagnosis of the ABS/EDL/TCS/ESP Mark 60
Description of the function
Chapter
Indication of faults by means of warning lights -K47-, -K14/33- and -K155-
Arrangement of warning lights
Pos. Denomination
2 Hand brake/brake fluid level warning light -K14/33-
3 ESP warning light -K155-
WARNING
Once the ABS warning light -K47- and the hand brake/brake fluid level warning light -K14/33-
have lit up, then the rear wheels can already lock when braking lightly.
Overview
Meaning ABS warning Hand brake/brake fluid ESP warning

light -K47- level warning light light -K155-
-K14/33-
Ignition on (if the systems are OK, the lights up lights up lights up
lights go out after approx. 3 s)
ESP failure or ESP deactivated by means does not does not light up lights up
of button; ABS, EDL and EBD are active light up
System O.K. does not does not light up does not

385
light up light up
ESP intervention does not does not light up flashes

light up
ABS/EDL/ESP failure; EBD remains active lights up does not light up lights up
(e.g. a wheel speed sensor is defective)
ABS/EDL/ESP/EBD failure; (e.g. a wheel lights up lights up lights up

speed sensor is defective)
Brake fluid level too low; all systems does not lights up does not
O.K. light up light up
Warning light -K47-
If the ABS warning light (-K47-) -1- does

be:
-a- the supply voltage is less than 10 V
-b- an ABS fault is present
The antilock braking system is switched off

if an ABS fault -b- is present. The EBD
function (Electronic Brake pressure
Distribution) is furthermore active while the
conventional brake system remains fully
operational. Interrogate the fault memory
Chapter.
-c- a sporadic fault existed on a wheel

speed sensor after the last vehicle start
In case of a wheel speed sensor fault -c-,

the ABS warning light goes out
automatically -K47- after restarting the
reached.
-d- the connection from the ABS control

unit -J104- to the dash panel insert -J218- is
interrupted binder Current Flow
Fitting Locations
-e- Dash panel insert defective
386
Warning light -K47- and -K14/33-
If the ABS warning light goes out (-K47-)

-1- but the warning light for the hand
brake/brake fluid level (-K14/33-) -2-
t
remains lit and 3 warning tones are
audible, the following can be the causes
of the fault:
a- the brake fluid level is too low
b- the hand-brake is still applied
the switch -F9- for the warning light

c - -K14/33- is defective or incorrectly
adjusted
a fault in the operation of the hand

brake/brake fluid level warning light
d - -K14/33- binder Current Flow
Fitting Locations

t light (-K14/33-) -2- light up, then the ABS
system and the EBD (Electronic Brake
pressure Distribution) have failed.

light (-K14/33-) -2- light up and 3 warning
t
tones are audible, then the ABS and the
EBD (Electronic Brake pressure
Distribution) have failed.
Note
The warning light for the hand brake/brake

fluid level (-K14/33-) -2- only lights up after
exceeding a speed of 10 km/h once or an
engine speed of 2000 rpm.
WARNING
Once the ABS warning light -K47- and the

hand brake/brake fluid level warning light
-K14/33- have lit up, then the rear wheels
can already lock when braking lightly.
387
Warning light -K155-
If the ESP warning light (-K155-) -3- does

be:
There is a fault which exclusively effects

the ESP. The ABS/EDL and EBD safety
systems on the vehicle remain fully
functional. Interrogate the fault memory
Chapter.
Short circuit to positive in ESP button

a-
-E256-
Short circuit to earth in the operation of

b-
the ESP warning light -K155-
the connection from the ABS control unit

-J104- to the dash panel insert -J218- is
c
interrupted binder Current Flow
-
Fitting Locations
the ESP system was switched off using

d-
the ESP button -E256-
If the ESP warning light lights up -K155- for

approx. 100 milliseconds after switching on
the ignition, a coding without ESP control
was entered.
If the ESP warning light -K155- flashes

while driving, the ESP system is operating
in regulating mode.
Warning light -K47-, -K14/33- and -K155-

t light (-K14/33-) -2- flash and the ESP
warning light (-K155-) remains lit, the
control unit is not yet coded.
Electrical test ABS/EDL/TCS/ESP Mark 60
388
t Measuring tool set -V.A.G 1594/A-
t Test box -V.A.G 1598/A-
t Adapter -V.A.G 1598/36-
The test steps Anchor apply only to vehicles with ABS/EDL/TCS/ESP,
for which the self-diagnosis does not indicate the fault source. In this case the full electric
t
inspection must be carried out.
for which the self-diagnosis gives a direct indication of the fault source. Then only perform
t
the test steps recommended in the fault table (targeted approach).
Test requirements
Chapter
Note
The following 2 work steps do not apply to the 1.6 ltr./55 kW engine.
Remove air filter

air filter.
and lay it aside.
Connect test box -V.A.G 1598 A- with

Chapter
Contact assignment of the plug connection -T16a- (diagnostic connection) with the vehicle
system tester -V.A.G1552-
389
Chapter

Note
Plug contacts which have not been listed

are not used.
1 - Voltage supply of battery + (via S162)
2 - Plug connection -T16a/7-, -K- cable
Signal cable of the longitudinal

3 - acceleration sender -G251- for four-
wheel drive vehicles
4 - Voltage supply terminal 15 (via S9)
Earth cable of the longitudinal

Lateral acceleration sender -G200-

6-
(signal)
Voltage supply of the longitudinal

Only for vehicles with navigation

8-
system
Jumper to contact 12 for four-wheel

9-
drive vehicles
Only on vehicles equipped with

10
navigation system and Xenon
-
headlights
Data BUS cable binder Current Flow

11
-
Fitting Locations
Jumper to contact 38 for front-wheel

12
drive, jumper to contact 9 for four-
-
13 - TCS/ESP button-E256-
Jumper to contact 38 for vehicles with

14 -
TCS
15 Data BUS cable binder Current Flow

- Diagrams, Electrical Fault Finding and
390
Fitting Locations
16 - Earth
17 - not assigned
18 Voltage supply of the brake pressure

- sender -1--G201-
Earth cable of the brake pressure

19 -
sender -1--G201-
Signal cable of the brake pressure

20 -
sender -1--G201-
21 a 23 - not assigned
Earth cable of the lateral acceleration

24
sender -G200- and the yaw rate sender
-
-G202-
25 - not assigned
Voltage supply of the lateral

26
acceleration sender -G200- and the
-
yaw rate sender -G202-
32 - Voltage supply of battery + (via S163)
33 - Front right wheel speed sensor -G45-
34 - Front right wheel speed sensor -G45-
36 - Rear left wheel speed sensor -G46-
37 - Rear left wheel speed sensor -G46-
Jumper to contact 12 for front-wheel

38
drive and ESP, jumper to contact 14 for
-
front-wheel drive and TCS
41 - Brake light switch -F-
42 - Rear right wheel speed sensor -G44-
43 - Rear right wheel speed sensor -G44-
47 - Earth
391
Voltage supply of the ABS hydraulic pump -V64- - Perform test step 1
Voltage supply of the valves in the hydraulic unit - Perform test step 2
Voltage supply of the control unit -J104- - Perform test step 3
Function of the brake light switch -F- - Perform test step 4
Jumpers - Perform test step 5
Resistance of the front right speed sensor -G45- - Perform test step 6
Resistance of the front left speed sensor -G47- - Perform test step 7
Resistance of the rear right speed sensor -G44- - Perform test step 8
Resistance of the rear left speed sensor -G46- - Perform test step 9
Voltage signal of the front right speed sensor -G45- - Perform test step 10
Voltage signal of the front left speed sensor -G47- - Perform test step 11
Voltage signal of the rear right speed sensor -G44- - Perform test step 12
Voltage signal of the rear left speed sensor -G46- - Perform test step 13
Function of the ABS warning light -K47- - Perform test step 14
Function of the hand brake/brake fluid level warning light -K14/33- - Perform test step 15
Function of the ESP warning light -K155- - Perform test step 16
Function of the TCS/ESP button -E256- - Perform test step 17
Actuation of the steering angle sender -G85- - Perform test step 18
Actuation of the lateral acceleration sender -G200- - Perform test step 19
Actuation of the yaw rate sender -G202- - Perform test step 20
Actuation of the longitudinal acceleration sender -G251- - Perform test step 22
Test of the data BUS cable - Perform test step 23
Voltage supply for -V.A.G 1552-, plug connection -T16a- - Perform test step 24
Resistance of the -K- cable for the self-diagnosis, plug connection -T16a- - Perform test step 25
Test table
392
Note
The denominations of the bushes of the test box -V.A.G 1598 A- with adapter -V.A.G
1598/36- are identical to the contact denominations of the ABS control unit -J104- in the
t
current flow diagram binder Current Flow Diagrams, Electrical Fault Finding and Fitting
Locations
plugs of the test devices and measuring cables (with contact spray -G 000 700 04-) and
more specifically for nominal values below 10 , repeat the resistance measurement on
the component.
Test -V.A.G Test covers Test Specifie Measures for deviations from
l
step 1598 A- conditions d value nominal value
bushes
additional
works
1 1 + 47 Voltage supply of the Ignition 10.0 - Test wiring of contact -T47a/1-

l
hydraulic pump -V64- off 14,5V via fuse S163 to battery +.
(terminal 30) at the
control unit -J104- Test wiring of contact to earth
Current flow diagrams,
Electrical fault finding and
Fitting locations
2 32 + 16 Voltage supply of the Ignition 10.0 - Test wiring of contact

l
valves in the hydraulic off 14,5V -T47a/32- via fuse S162 to
unit -N55- (terminal 30) battery +.
at the control unit -J104-
Test wiring of contact -47a/16-
to earth Current flow
diagrams, Electrical fault
finding and Fitting locations
3 4 + 47 Voltage supply (terminal Ignition 10.0 - Test wiring of contact -T47a/4-

l
15) of the control unit on 14,5V via fuse S13 and ignition
-J104- starter switch.
Test wiring of contact -47a/47-

to earth Current flow
393
test step 4a
4 41 + 47 Brake l Ignition off If necessary set brake light switch

light 0.0 - 0.5 Chapter.
switch Brake pedal not V
l
-F- actuated Replace brake light switch

Chapter.

003.
Brake pedal actuated 10.0 - Check contact 1 of the brake light

14.5 V switch -F- to fuse S13.
4a Brake Measuring range 200 Test wiring for open circuit.

l
light set
switch Repair wiring according to the
-F- Disconnect the multi- current flow diagram Current
pin connector -T47a- flow diagrams, Electrical fault
from the control unit finding and Fitting locations
-J104-
Pull out the multi-pin max.

connector from the 1.5
brake light/brake pedal
switch

circuit

41 (control unit) to
contact 1 (brake light
switch)
Set measuring range

l
20 M
Remove fuse S13

earth
394
Test -V.A.G 1598 Test l Test conditions Specified Measures for deviations from
step A- bushes covers value nominal value
additional works
5 12 + 38 Jumper l Ignition off max. 1.5 Test wiring of contact

14 + 38 9/12/14 to contact 12/38 for
9 + 12 Detach multi-pin open circuit.

connector -T47a-

with adapter -V.A.G
1598/36-

circuit
l
bushes
additional
works
6 33 + 34 Resistance of the Ignition 1.0...1.3 Separate plug connection on speed

l
front right speed off k sensor.
sensor -G45-
Check wiring according to current

flow diagram.
Throughout the test, do not move

cables Current flow diagrams,
Electrical fault finding and Fitting
locations

Chapter.

l
front left speed off k sensor.
sensor -G47-

flow diagram.

395
locations

Chapter.
Switch on measuring range: resistance measurement (2k)
l
bushes
additional
works

l
rear right speed off k sensor.
sensor -G44-

flow diagram.

locations

Chapter.

l
rear left speed off k sensor.
sensor -G46-

flow diagram.

locations

Chapter.
Switch on measuring range: voltage measurement (2 V )
396
bushes additional

works

sensor -G45- Turn front right
wheel by
approx. 1 turn Check wheel speed sensor -G45-
per sec. to ensure it is correctly

value block Chapter, display
group number 001.

sensor -G47- Turn front left
wheel by

group number 001.

sensor -G44- Turn rear right
wheel by
approx. 1 turn C
per sec.

sensor -G46- Turn rear left
wheel by

group number 001.
397
Test -V.A.G Test covers l Test conditions Specified value Measures for deviations
ste 1598 A- from nominal value
14 - Function of The fault memory was The warning If the ABS warning light
the ABS interrogated and there light -K47- does not light up:
warning l is no fault in the fault lights up for
light -K47- memory of the control approx. 2 Check wiring according to
unit -J104- seconds and current flow diagram.

goes out Current flow diagrams,
l Ignition off Electrical fault finding
and Fitting locations
The multi-pin Check dash panel insert,

connector is inserted fault in the dash panel
l
on the control unit insert Electrical
-J104- and locked System; Rep. gr.90
Switch on ignition
Test -V.A.G Test covers l Test conditions Specified value Measures for deviations
ste 1598 A- from nominal value
p bushes additional

works
15 - Function of the Brake fluid level The warning Check the brake fluid
l
hand brake/brake is O.K. light -K14/33- level warning contact
fluid level lights up for -F34- in the screw cap of
warning light l Ignition off approx. 2 the brake fluid reservoir.
-K14/33- Multi-pin seconds and
goes out Check wiring according to
connector the current flow diagram
inserted on
l Current flow diagrams,
control unit Electrical fault finding and
-J104- and Fitting locations
locked
Check dash panel insert,
Switch on fault in the dash panel

ignition insert Electrical
System; Rep. gr.90
Functional test: ESP warning light -K155-
Test -V.A.G Test covers l Test conditions

ste 1598 A-
additional works
398
p bushes
16 - Function of l Ignition off The warning light Test wiring for open circuit
the ESP -K155- lights up and for short-circuit to
warning Multi-pin for approx. 2 positive.
light -K155- connector seconds and
l inserted on goes out If the warning light -K155-
control unit remains lit:
-J104- and locked
Test the wiring of the dash
Switch on panel insert for short-circuit

ignition to earth. Current flow
Check dash panel insert,

fault in the dash panel
insert.
Check ESP button -E256-.
Test voltage supply relay for

warning light -K155-.

Fitting locations
Functional test: Warning light -K155- for the function of the ESP button -E256- in test step 17;
voltage supply (20 V=) in test step 17a
Test -V.A.G Test covers l Test conditions Specified value Measures for deviations from
ste 1598 A- nominal value
17 - Function of l Ignition off The warning

the light -K155-
TCS/ESP The function of lights up for
button the ESP warning approx. 2
-E256- l light -K155- was seconds and
tested with test goes out
step 17
Multi-pin
connector
l inserted on
control unit -J104-
and locked
Switch on

ignition
399
Operate ESP Warning light Perform test step 18a.

button -K155- comes
on
Operate ESP Warning light

button once again -K155- goes out
17a 16 + Function of Switch off Test wiring of contact -47a/16-

13 the ignition (control unit) to earth.
TCS/ESP
button Disconnect the Test wiring of contact
-E256- multi-pin -T47a/13- (control unit) to

connector from contact -T4f/2- (ESP button)
the control unit for open circuit or short-circuit
-J104- to positive or to earth.
Connect -V.A.G
1598 A- with
adapter -V.A.G
1598/36-
Switch on

ignition
Button -E256- not 3,5-5,0 V Test wiring for open circuit and

pressed and short-circuit to positive or to
warning light earth.
-K155- lights up
Button -E256- 8,0-14,5 V Test voltage supply of contact

held pressed and -T4f/1- (ESP button) via fuse

warning light S13 for open circuit Current
-K155- lights up flow diagrams, Electrical fault
Replace ESP button

Electrical System; Rep.
gr.96

voltage measurement (20 V =) in test step 18, resistance measurement (200 )/(20 ) in test
step 18a
18 - Earth connection l Ignition off Test wiring of contact -T6w/4-

and voltage (steering angle sender) to
supply of the Disconnect the
multi-pin connector
400
steering angle -T47a- from the fuse S15 for open circuit.
sender -G85- control unit -J104-
Repair wiring according to
Disconnect the plug the current flow diagram

connection from the Current flow diagrams,
steering angle Electrical fault finding and
sender Fitting locations
Test the voltage

supply of the

steering angle
sender at the plug
connection -T6w-
Test wiring between 10.0-

contact -T6w/4- and 14.5V
contact -T6w/1-
l Ignition on Test wiring of contact -T6w/5-

(steering angle sender) to
Test wiring between 10.0- fuse S13 for open circuit

contact -T6w/5- and 14.5V Current flow diagrams,
contact -T6w/1- Electrical fault finding and
Fitting locations
18a 11 + Cables for Measuring range

l
15 steering angle 200 set
sender -G85-
Connect -V.A.G 1598

A- with adapter
-V.A.G 1598/36-
Check the following

line connections for
an open circuit:
Wiring of contact max. Test wiring for open circuit.

-T6w/3- (steering 1.5
angle sender) with
contact -T47a/11- the current flow diagram

(control unit) Current flow diagrams,
Wiring of contact Fitting locations
-T6w/2- (steering

angle sender) with
contact -T47a/15-
(control unit)
Wiring of contact

-T6w/1- to earth
Measuring range 20
l
MQ set
401
Remove fuse S15
Check cables for

short-circuit to

lateral
acceleration Measuring range 200
l
sender -G200- set
Disconnect the multi-

pin connector -T47a-
from the control unit
-J104-

with adapter -V.A.G
1598/36-
Disconnect the plug

connection -T3n- from
the lateral acceleration
sender
Test wiring for open max. Test wiring for open circuit.

circuit 1.5
Wiring of contact the current flow diagram

-T3n/1- (lateral Current flow diagrams,

acceleration sender) Electrical fault finding and
with contact -T47a/6- Fitting locations
(control unit)
Wiring of contact
-T3n/2- (lateral

(control unit)
Wiring of contact max.

1.5
402
-T3n/3- (lateral
(control unit)
l
set

earth
Test V.A.G Test covers l Test conditions Specifie Measures for deviations from
step 1598 A d value nominal value

lateral
acceleration Measuring range
l
sender -G200- 200 set
Disconnect the multi-

-J104-
Connect -V.A.G 1598

1598/36-
Disconnect the plug

connection -T3m-
from the yaw rate
sender

Test wiring for open circuit.
circuit
Wiring of contact max. Repair wiring according to

-T3m/1- (yaw rate 1.5 the current flow diagram

sender) with contact Current flow diagrams,
-T47a/6- (control unit) Electrical fault finding and
Fitting locations
Wiring of contact
-T3m/2- (yaw rate
-T47a/24- (control
403
unit)
Wiring of contact
-T3m/3- (yaw rate

-T47a/26- (control
unit)
Measuring range
l
20 M set
Check cables for

short-circuit to

brake
l
sender -1-- set
G201- Disconnect the multi-
-J104-

with adapter -V.A.G
1598/36-
Disconnect the plug

connection -T30- from
the brake pressure
sender -1--G201-
Test wiring for open Test wiring for open circuit.

circuit
Wiring of contact Repair wiring according to the

-T30/1- (brake pressure max. current flow diagram

sender) with contact 1.5 Current flow diagrams,
-T47a/19- (control unit) Electrical fault finding and
Fitting locations
Wiring of contact
-T30/2- (brake pressure
404
Wiring of contact
-T30/3- (brake pressure
l
set

earth
ste 1598 d value from nominal value
bushes

longitudinal
acceleration l Measuring range 200 set
sender -G251- Disconnect the electrical plug
connection from the
longitudinal acceleration
sender -G251-

control unit -J104-

1598/21-
Check the cables between max. Test the wiring

the multi-pin connector of the 1.5 according to the current
longitudinal acceleration flow diagram binder
sender -G251- and the multi- Current Flow Diagrams,
pin connector of the control Electrical Fault Finding
unit -J104- for open circuit and Fitting Locations
Check cables for short-circuit Check wiring according

to positive or to earth to the current flow
405
diagram Current flow
diagrams, Electrical
fault finding and Fitting
locations
11 + 15 Data l Ignition off

BUS
23 cables l Measuring range 200 set
control units connected to
the data BUS

with adapter -V.A.G
1598/33-
Test wiring for open circuit
to the steering angle

sender
to the engine control unit
to the automatic gearbox

control unit 1)
Wiring of contact -T47a/11- max. Test wiring for open circuit.

(control unit) to contact 1.5
-T6w/3- (steering angle Repair wiring according to the
sender -G85-) current flow diagram Current
flow diagrams, Electrical fault
Continue to the connected finding and Fitting locations

control units
Wiring of contact -T47a/15-

(control unit) to contact
-T6w/2- (steering angle
sender -G85-)
Continue to the connected

control units
l Measuring range 20 set
406
earth
1)
Only on vehicles with automatic gearbox.
ste 1598 A- d value from nominal value
24 - Voltage supply for l Ignition on 10.0- Test wiring of -T16a/4- to

the vehicle system 14.5V earth.
tester -V.A.G 1552-, Connect the handheld
plug connection multimeter -V.A.G 1526 Test wiring of -T16a/1-

-T16a- A- with the measuring via S5.
tool set -V.A.G 1594 A-
to -T16a-1) Repair wiring according
to the current flow
Test wiring between diagram Current flow

contact -T6a/4- and diagrams, Electrical fault
contact -T16a/1- finding and Fitting
locations
1)
Contact assignment of the plug connection for the voltage supply and the self-diagnosis
with the vehicle system tester -V.A.G 1552- Chapter.
25 - Resistance of the l Ignition off

-K- cable for the
self-diagnosis, plug Measuring range max. Test wiring of contact
l
connection -T16a- 200 set 1.5 -T16a/7- to contact
-T47a/39-.
Disconnect the
multi-pin connector Repair wiring according to
-T47a- from the the current flow diagram

control unit -J104- Current flow diagrams,
Connect -V.A.G Fitting locations
1598 A- with
adapter -V.A.G
407
1598/33-
Test wiring
between contact
-T16a/7- and
contact -T47a/39-
Measuring range Repair wiring according to

l
20 M set the current flow diagram

Check cables for Electrical fault finding and
short-circuit to Fitting locations

408
Brake, brake mechanics
Repairing the front brake

Changing the brake pads of the front brake - Mounting instructions
When changing the pad, observe the following:

Check the protective collar of the piston for brake caliper.
Replace the protective collar if damaged.
When replacing the collar:
Check the contact surfaces of the brake piston and the brake caliper for any dirt (oxydation).
Carefully clean the piston as well as the brake caliper if dirty and replace the sealing sleeve.
Check the brake piston and the brake caliper (corrosion, grooves on the outside of the cylinder surface),
replace the brake caliper completely if damaged.

For the piston of the brake caliper, press into the initial position:
Check if the piston can be slightly pressed into the brake caliper.
If the piston cannot be slightly pressed into the brake caliper:
Check and clean the brake piston as well as the brake caliper, replace sealing sleeve and protective collar.
Replace the brake caliper completely if damaged.
Repairing front brake, the floating caliper disc brake FS-III
t Piston jig -MP 9-403-
t Bleeding bottle (commercially available)
t Solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
Note
t Observe the instructions for changing the pad Chapter.
After replacing the brake pads, depress brake pedal firmly several times when the vehicle
t is stationary to ensure the brake pads are properly seated in their normal operating
position.
Before removing a brake caliper or separating a brake hose from the brake caliper, the
t
brake pedal must be locked; e.g. with brake pedal load -V.A.G 1238/B-.
Use a bleeding bottle, that only comes into contact with the brake fluid, to drain brake fluid
t from the brake fluid reservoir. Brake fluid is toxic and must never be sucked into your
mouth via a hose!
t Already used brake fluid must never be used again.
409
t Tightening torque of the wheel screws: 120 Nm
1- 4 Nm
2- Brake disc
t Thickness: 22 mm
t Wear limit: 19 mm
t if worn always replace axle-wise
t unscrew the brake caliper before removing
Do not use force to separate the brake discs from the wheel hub, if necessary use rust
t
solvent, as you could otherwise damage the brake discs.
t Technical data Chapter
3- Brake pads
with wear indicator - with a corresponding wear (limit: 2 to 3 mm) the warning light in the
t
dash panel insert lights up
t Thickness 19.5 mm including support plate
t Wear limit: 7 mm including support plate
t Inspect thickness BookletOctavia
t always replace axle-wise
410
t Observe the instructions for changing the pad Chapter
t 05.98 : do not interchange the inside and outside brake pads Chapter
4- Brake caliper
t removing:
Remove brake pads -Pos. 3
Insert brake pedal load.
Unscrew brake hose -Pos. 7- from brake caliper
t Installing:
Install brake pads -Pos. 3-
Screw brake hose -Pos. 7- to brake caliper
Take out brake pedal load.
Bleeding Brake System Chapter
t repairing Chapter
5- Guide bolt, 30 Nm
6- Cap
7- Brake hose with banjo union and hollow screw
t cannot be disassembled, must be fully replaced
8- Wheel-bearing housing
9- 8 Nm
clean the inner surface of the hole before inserting the wheel speed sensor and coat with a
t
solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
11 - Cover plate
12 - 10 Nm
13 - Wheel bearing
14 - Circlip
411
15 - Wheel hub with pulse rotor
16 - Wheel hub without pulse rotor
Removing and installing brake pads/brake caliper (FS III)
Observe the instructions for changing the pad Chapter.
Removing
Remove wheels.
Note
When removing mark the brake pads you intend to keep using. Install in the same location,
t
as otherwise this may cause uneven braking!
t Do not unscrew the brake hose when replacing the brake pad.
Disconnect the plug connection for the brake pad wear indicator (where the vehicle is
fitted with this).
412
Remove caps -2-.
Unscrew and remove the two guide bolts
from the brake caliper.
Remove the brake caliper housing and

secure with wire in such a way that the
weight of the brake caliper does not
burden or damage the brake hose.
Take out the brake pads from the brake
caliper housing.
Install
Note
Before inserting new brake pads, press

piston with piston jig into the brake caliper.
Drain the brake fluid from the brake fluid
reservoir using a ventilation bottle before
pushing back.
Otherwise brake fluid can flow out and lead

to damage - if brake fluid was added in the
meantime.
WARNING
Brake fluid is toxic and must never be

sucked into your mouth through a hose.
Clean the brake caliper housing.
Note
Use spirits only to clean the brake caliper

housing.
413
Push piston back with piston setting and
timing device -MP 9-403-.
Insert brake pads.
05.98 : Do not interchange the inside and

outside brake pads.
Outer pad: black three-finger clip
Inner pad: white coloured piston side
First position the brake caliper housing at
the bottom -arrow-.
Mount the brake caliper housing with

brake pads onto the wheel bearing
housing.
The pin of the brake caliper housing -arrow-

must be located behind the guide of the
wheel bearing housing!
Screw the guide bolt into the brake
caliper housing and tighten to 30 Nm.
Connect the plug connection for the
brake pad wear indicator (where the

vehicle is fitted with this).
Insert both caps -2-.
Attach the wheels.
Note
After replacing the brake pads, depress

brake pedal firmly several times when
t the vehicle is stationary to ensure the
brake pads are properly seated in their
normal operating position.
Check brake fluid level after replacing the

t brake pads, if necessary top up with
brake fluid.
414
Repairing the front wheel brake, brake caliper FN -3
Note
position.
t
mouth via a hose!
t Tightening torque of the wheel screws: 120 Nm.
415
1- 4 Nm
2- Brake disc
t the max. axial run-out is not marked
t released combination of a brake disc without marking and a wheel hub with marking
t with a fixing hole for the wheel hub
t
3- Brake disc
t with a marking approx. 5 mm wide for marking the maximum wheel run-out
t released combination of a brake disc with marking and a wheel hub without marking
t with 5 fixing holes for the wheel hub
416
t
4- Brake pads
with wear indicator - with a corresponding wear (limit: 2 to 3 mm) the warning light in the
t
dash panel insert lights up
t Inspect thickness BookletOctavia
5- Retaining spring
t insert in both bores of the brake caliper housing.
t replace after each brake pad replacement
6- Brake carrier
t must be assembled with sufficient grease on the guide bolt, supplied as a spare part
if there is any damage to the protective caps or guide bolts fit a repair set (use the enclosed
t
grease packing to lubricate the guide bolts)
7- Brake caliper
t removing:
Unscrew brake hose -Pos. 10- from brake caliper.
t Installing:
Screw brake hose -Pos. 10- to brake caliper.
t repairing Chapter
417
t removing and installing -Pos. 4
9- Cap
10 - Brake hose with banjo union and hollow screw
t must be replaced completely, do not dismantle
11 - 124 Nm
t Clean ribbing on the underside
13 - 8 Nm
t
solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste).
15 - Cover plate
16 - 10 Nm
17 - Wheel bearing
18 - Circlip
t with and without marking for minimum axial run-out
In combination with the wheel hub without marking of the min. axial run-out and the brake
t disc without marking of the min. axial run-out or permissible vice versa, the reduction of the
overall axial run-out of the brake FN 3 is then not effective.
Removing and installing brake pads/brake caliper FN 3

418
Observe the instructions for changing the pad Chapter.
Removing
Remove wheels.
Note
t
Note
Remove caps -arrows-.
Disconnect the plug connection for the

Lever the retaining spring of the brake
pads out of the brake caliper housing

-arrow- using a screwdriver and remove.
419
Unscrew and remove the two guide bolts
from the brake caliper.

Take out the brake pads from the brake
caliper housing.
Clean the brake caliper, in particular the

adhesive surfaces for the brake pads
must be free from glue residues and
grease.
Note
Only use alcohol to clean the brake caliper

housing.
Install
Directional brake pads
1 - right brake pad on the piston side
2- left brake pad on the piston side
In the installed condition, the arrow on the

backing plate of the brake pad must point
downwards. Please pay attention to this!
Note
Before inserting the new brake pads, press

the piston with piston jig into the cylinder.
Drain the brake fluid from the brake fluid
reservoir using a ventilation bottle before
pushing back. Otherwise brake fluid can
flow out and lead to damage if brake fluid
was added in the meantime.
WARNING

sucked into your mouth via a hose!
420
Push back piston.
Insert inner brake pad.
Insert outer brake pad.
Remove the protective foil from the
backing plate of the brake pad.
421
Screw the brake caliper housing with both
guide bolts -arrows- to the brake carrier.
Tightening torque: 30 Nm
Connect the plug connection for the

Insert both caps -arrows-
Insert the ends of the retaining spring

into the holes of the brake caliper
housing -arrow A- and subsequently press

the retaining spring behind the brake
caliper -arrow B-.
Attach the wheels.
Note
After each brake pad replacement,

forcefully apply the brake pedal
t
repeatedly to ensure the brake pads go
into their normal operating position.

t brake pads, if necessary top up with
brake fluid.
422
Removing and installing brake discs (FN 3)
Note
Brake judder, brake pulsations or steering wheel torsional vibrations can occur with the
t brake FN 3. This is caused by a too great overall axial run-out in the system brake disc -
wheel hub.
In order to reduce the overall axial run-out, the maximum and minimum axial run-out of
t
the brake disc and the wheel hub is marked with an ink-jet marking.
When handling a fault due to a too great overall axle run-out, the wheel hubs and the
t brake discs which are not marked must be replaced with marked parts. Assignment
If used brake discs with a marking and a 5-hole fixing for wheel hubs are reinstalled, the
t
position of the brake disc to the wheel hub must be marked before removal.
The combination of marked brake disc/unmarked wheel hub or unmarked brake disc and
t
marked brake disc is allowed.
The combination of the left vehicle side components without marking and the right vehicle
t
side components with marking or vice versa is also allowed.
Pay attention that the reduction of the overall run-out on the brake FN 3 is not effective for
t
the stated combinations.
t Only replace brake discs axle-wise.
t
Removing
Remove wheel.
Note
Do not remove the brake hose from the brake caliper.
Remove the brake carrier with the brake caliper and secure with wire in such a way that
the weight of the brake caliper does not burden or damage the brake hose.
Remove the brake disc/wheel hub connecting screw.
Remove the brake disc.
When handling a fault due to a too great overall run-out of the axle
Remove wheel hub Chapter.
Install
423
When handling a fault due to a too great overall run-out of the axle
Install a new wheel hub -1- with an ink-jet

marking approx. 3 mm wide for marking
the minimum axial run-out -arrow A- in
the wheel bearing housing Chapter.
Install a new brake disc -2- on the wheel

hub with an ink-jet marking approx. 5
mm wide for marking the maximum axial
run-out -arrow B-.
Fitting position:
Install the brake disc on the wheel hub in

such a way that the marking of the
minimum axial run-out (wheel hub) and the
maximum axial run-out (brake disc) are
located opposite each other.
Vehicles without a fault
After changing the brake disc (old wheel

hub/new brake disc), a minimisation of
t
the axial run-out is not possible on used
vehicles.
The brake discs can be installed without

t
paying attention to the fitting position.
Install brake disc.
Further installation occurs in reverse
order.
Tightening torques:
Brake disc to wheel hub 4 Nm
Brake carrier with brake caliper to wheel bearing housing 124 Nm
Wheel bolt 120 Nm
424
Repairing rear wheel brake - front wheel drive (drum brake)
Replacing the brake shoes of the rear brake - Mounting instructions
When changing the brake shoes, pay attention to the following points:
Check the protective collars of the wheel-brake cylinders.
Replace the wheel-brake cylinders if the protective collars are damaged.
Check the wheel-brake cylinder for tightness Fig..
Replace the wheel-brake cylinder if leaking.
Check if the pistons can be slightly pressed into the brake cylinder.
If the pistons cannot be slightly pressed into the brake cylinder:
Replace the wheel-brake cylinder.
Removing and installing rear wheel brake
t Measuring tool for brake drum -MP 5-407-
t Dial gauge (measuring range 0 -10 mm)
Note
After replacing the wheel-brake cylinder, brake carrier and brake shoe, forcefully apply the
t
brake pedal once to ensure the brake shoes go into their normal operating position.
mouth through a hose.
Use the brake pedal load, e.g. -V.A.G 1238/B-, before removing a brake cylinder, a brake
t
carrier or before separating a brake pipe from the wheel-brake cylinder.
425
1- 4 Nm
2- Brake drum
t Brake drum diameter 230 mm
t Wear limit 231.0 mm
clean carefully, and check for wear, damage, dimensional accuracy and perfect brake
t
surface
Check noncircularity by means of a special tool -MP 5-407- and the dial gauge (measuring
t
range 0 - 10 mm).
Permissible noncircularity 0.03 mm. If the measured value is greater than 0.03 mm, the
brake drum must be replaced BookletOctavia.
3- Cap
t press off Fig.
t inserting Fig.

426
7- Self-locking screw, 50 Nm + 60
8- Brake carrier with brake shoe
t removing:
Resetting brake Chapter.
Remove the brake drum.
Unscrew brake pipe.
Remove brake carrier.
t Installing:
Install brake carrier.
Screw on brake hose.
Install the brake drum.
Bleeding Brake System Chapter
t repairing Chapter.
9- Axle body
10 - Axle stud
11 - 8 Nm
t
427
Resetting brake
Use a screwdriver to push the wedge up

through a hole for the wheel screws in the
brake drum.
Repairing rear brake
t Hook (commercially available)
t Plastic wedge 3409
Note
After working on the rear axle brake:
t Put hand-brake back.
t Forcefully actuate the brake pedal once.
428
1- Spring cap
t to remove push against pressure spring and turn 90
2- Pressure spring
3- Locating spring
4- Pressure rod
t Coat the points of contact with solid lubricant paste -G 000 650- (e.g. Wolfrakote Top Paste)
5- Wedge
when removing and installing the brake drum push up through a hole for wheel screw
t
Chapter
6- Wheel-brake cylinder
t Check tightness Fig.
t Repairs not allowed
t removing:
Unscrew brake hose.
Remove wheel-brake cylinder.
t Installing:
429
Install wheel-brake cylinder.
Screw on brake pipe.
7- 8 Nm
8- Tensioning sleeve
9- Brake carrier
10 - Cap
t remove to check brake pad thickness Fig.
11 - Brake shoe
t Observe the instructions for changing the brake shoe Chapter
t Minimum pad thickness without supporting shoe 2.5 mm
Check thickness Fig., visual inspection through the inspection hole in the brake carrier, if
t
necessary BookletOctavia
t Always replace brake pads axle-wise
12 - Tension spring
13 - Bottom retractor spring
t Coat the contact points with solid lubricant paste -G 000 650-
14 - Top retractor spring
15 - Brake shoe with lever for hand-brake
t Observe the instructions for changing the brake shoe Chapter
t Setting the hand-brake Chapter
430
Checking the wheel-brake cylinder for
tightness
Lift off dust cup.
Use a plastic wedge -3409- for this

purpose.
If there is any brake fluid in the dust cup,
replace wheel-brake cylinder.
Make sure the dust cup is not damaged

when lifting it off.
Checking the brake pad thickness through

the inspection hole in the brake carrier.
Unclip the cap from the brake carrier
-arrow-.
Checking the brake pad thickness

through the inspection hole in the brake
carrier. Minimum pad thickness without

supporting shoe (wear dimension) 2,5
mm.
Note
Pay attention to pads greased with brake

fluid or grease.
Removing and installing brake shoes
t Hook (commercially available)
Removing
Remove wheels.
Remove spring cap with pressure springs.
431
Lever out the brake shoes in the
-direction of arrow- behind the bottom

support plate using a screwdriver.
Lay the brake shoes on the bottom
support plate.
Unhook the retractor spring at the
bottom.
Unhook the hand-brake cable.
Carefully guide the brake shoes out

between the wheel hub and the brake
carrier.
Tighten the brake shoe in the vice.
Unhook the tension spring -1- for wedge
-2-.
Unhook the retractor spring at the top -3-
with hook -A-.
Unhook the locating spring -1- with hook
-A-.
Remove the pressure rod -2- and the
wedge -3- from the brake shoe.
Install
432
Insert the locating spring in the brake
shoe and position the brake shoe on the
pressure rod.
Grease the contact point of the pressure
rod with solid lubricant paste -G 000

650-, e.g. Wolfrakote Top Paste.
Hook locating spring -1- with hook -A- in
the pressure rod -2-.
Insert the wedge -3- at the same time.
Fitting position:
The raised part -arrow- must remain visible

during installation.
Insert the brake shoe with brake lever in
the pressure rod.
Grease the contact point of the pressure
rod with solid lubricant paste -1-, e.g.

Wolfrakote Top Paste.
Hook on the retractor spring at the top
-3- with hook -A-.
Hook on the tension spring -1- for wedge
-2-.
Guide the brake shoes in between the
wheel hub and the brake carrier.
Position the brake shoe on the brake
cylinder piston.
Hook the hand-brake cable onto the
brake lever.
Insert the bottom retractor spring and lift

the brake shoe behind the bottom
support.
Grease the contact points of the bottom

retractor spring on the brake shoes with
solid lubricant paste -G 000 650-, e.g.
433
Wolfrakote Top Paste.
Insert the pressure spring with spring
cap.
Install the brake drum.
Forcefully actuate the brake pedal once.
Setting the hand-brake.
Attach the wheels.
Setting the hand-brake (drum brake)
Resetting of the hand-brake is not required after resetting of the rear brake due to automatic
resetting of the rear wheel-brake. Resetting is only required after replacing the hand-brake
cable, the brake carrier or the brake pads/brake shoes.
Note
Always replace self-locking adjusting nut.
Remove ashtray in centre console.
Release Phillips head screws.
remove Body Work; Rep. gr.68.
1- Handbrake cable
Put the hand-brake lever into the 4th
catch.
434
Tighten adjusting nut -arrow- until both
wheels are hard to turn by hand.
Release hand-brake and check whether
both wheels rotate freely, if necessary

release adjusting nut slightly.
435
Repairing rear wheel-brake - front-wheel drive (disc brake)
Changing the brake pads of the rear wheel disc brake - Mounting instructions


Note
position.
mouth via a hose!
t
436
1- 4 Nm
2- Brake disc, internally ventilated
t Diameter 256 mm
t Thickness 22 mm
t Wear limit 20 mm
t if worn replace axle-wise
3- Brake disc
t Diameter 232 mm
t Thickness 9 mm
t Wear limit 7 mm
4- Cap
t press off Chapter
t inserting Chapter
5- Self-locking twelve-point nut, 70 Nm + 40

437
7- 30 Nm + 90
8- Cover plate
9- Axle stud
11 - Axle body
t
13 - 8 Nm
14 - 30 Nm + 30
15 - Brake carrier with guide bolts and protective caps
fit a repair set if there is any damage to the protective caps or guide bolts; (use the
t
enclosed grease packing to lubricate the guide bolts)
16 - Brake hose with banjo union and hollow screw
t Tightening torque of the hollow screw: 35 Nm
t do not unscrew the brake line when replacing the brake pad
17 - Self-locking screw, 35 Nm
t always replace
18 - Brake caliper
t removing
438
Unscrew brake hose -Pos. 16- at brake caliper.
t Installing:
t repairing Chapter
t One must first adjust the hand-brake cable after undertaking repair or replacement work
The foot brake must not be applied beforehand!
19 - Brake pads
t Thickness 17 mm (including the support plate)
t Wear limit: 7.5 mm (including supporting plate)
t Check thickness: BookletOctavia
20 - Pad retaining spring
t always replace when changing the brake pads
Removing and installing brake pads
t Resetting and turning out tool -T10165-
t Assembly device -T10165/1-
439
Note
t
Removing
Remove wheels.
Unhook the handbrake cable from the brake caliper Chapter.
Unscrew the fixing screws of the brake

carrier while counterholding the guide
bolts.

Remove the brake pads and the pad
retaining springs.
Note

housing.
Clean the brake caliper housing; in

particular the adhesive surface for the
brake pad must be free from glue
residues and grease.
Install
Note
Before inserting new brake pads, press the

piston with a resetting and turning out tool
-T10165- into the cylinder. Drain the brake
fluid from the brake fluid reservoir using a
ventilation bottle before pushing back.
to damage if brake fluid was added in the
meantime.
WARNING
440
Insert the resetting and turning out tool

-T10165- in such a way that the surface
t
of the tool -T10165/1- is resting on the
brake caliper.
Use open-jawed spanner on a provided

t spanner surface -arrow A- if the piston is
difficult to move.
When adjusting the piston with a piston

resetting device the automatic
t
adjustment in the brake caliper is
destroyed.
Screw the piston by turning the knurled
wheel of the resetting tool -T10165- to

the right into the brake caliper.
Insert the new pad retaining springs

-arrows- and brake pads in the brake
carrier.
supporting plate of the brake pad.
Note
There are four self-locking screws in the

repair set, which must be fitted.
Secure the brake caliper housing using
new self-locking screws.
Counterhold at the guide bolt when

tightening.
Tightening torque: 35 Nm.
Hook the handbrake cable onto the brake
caliper Chapter.
Attach the wheels.
Note
t After each brake pad replacement,

441

t brake pads, if necessary top up with brake
fluid.
Setting the hand-brake (disc brake)
resetting of the rear wheel-brake. New adjustment is only necessary when the handbrake
cable and brake carrier are replaced or after replacing the brake shoes.
Note
t The brake system must be bled and fully operational.
t Always replace self-locking adjusting nut.
1- Handbrake cable
442
Put the hand brake lever in its rest
position. Tighten adjusting nut so far that
the levers -arrow- rise from the stops on
the brake calipers.
Check the distance between the lever
and the stop on the left and right brake

caliper using feeler gauges.
The distance -a- between the lever and the

stop on the left and right brake caliper
must not be less than a minimum of 1 mm
or exceed a maximum of 3mm.
Pull the handbrake on and release it
three times. This will position and set the

components.
If the hand-brake lever is in its rest

position, check whether both wheels
rotate freely, if necessary release
adjusting nut slightly.
Removing and installing hand-brake cable (drum brake)
Removing
Remove rear centre console Body Work; Rep. gr.68.
443
Release the adjusting nut -1- so far until
the hand-brake cable can be unhooked

from the compensating clamp -2-.
Raise vehicle.
Remove wheel.
Remove the brake drum.
Unhook the hand-brake cable from the
brake lever on the brake shoe.
Unclip hand-brake cable from the clip on
the rear axle body -arrow A- and unhook

from the brackets -arrows-.
Pull hand-brake cable -2- in the direction
of the arrow out of the guide tube -1-.
Install

order.
Note
When installing the hand brake cables,

t pay attention to the correct fitting
position Chapter.
Before setting the hand-brake, pretension

t the hand-brake cable with the adjusting
nut at the compensation clamp.
t Setting the hand-brake Chapter.
444
Removing and installing hand-brake cable (disc brake)
Removing

Raise vehicle.
Lift off the clip -1- with a screwdriver and
pull down to remove.
Press the hand-brake lever -2- in the
-direction of the arrow- and while doing

so unhook the hand-brake cable -3-.
445
Unclip hand-brake cable from the clip on
the rear axle body -arrow A- and unhook

from the brackets -arrows-.
Pull hand-brake cable -2- in -the direction
of the arrow- out of the guide tube -1-.
Install

order.
Note
When installing the hand brake cables,

t pay attention to the correct fitting
position Chapter.

446
Handbrake lever - Summary of components
1- Handbrake lever
t before the removal, remove the centre console Body Work; Rep. gr.68.
2- Door handle
pull it out towards the front, first of all press the catch peg below the door handle towards
t
the bottom using a small screwdriver
3- Covering for the hand brake lever
t removing: Body work; Rep. gr.68.
4- Centre console
t removing: Body work; Rep. gr.68.
5- 1.4 Nm
6- Nut, 18 Nm
7- Compensating clamp
8- Self-locking adjusting nut
t Setting the hand-brake:
Vehicles with drum brakes Chapter.
447
Vehicles with disc brakes Chapter.
9- Handbrake cable
t Fitting position of the hand-brake cables Fig.
t removing and installing (drum brake) Chapter
t removing and installing (disc brake) Chapter
different versions for the rear drum brake and disc brake Electronic Catalogue of Original
t
Parts.
10 - Switch for hand-brake control
t clipped
t replace if defective
Fitting position of the hand-brake cables
Note
Fitting position of the hand-brake cables is

identical on vehicles with drum or disc
brake (only version with drum brake is
shown).
The hand-brake cables are fastened with
clips to the axle body.
The clamping ring arrow -A- at the hand-
brake cable must rest in the centre of the

clip -arrow B-.
448
Repairing rear wheel-brake - four-wheel drive (disc brake)
Changing the brake pads of the rear wheel disc brake - Mounting instructions


Note
position.
mouth via a hose!
t
449
1- 80 Nm
2- Brake carrier with guide bolts and protective caps
fit a repair set if there is any damage to the protective caps or guide bolts; (use the
t
enclosed grease packing to lubricate the guide bolts)
t always replace
4- Brake hose with banjo union and hollow screw
t Tightening torque of the hollow screw: 35 Nm
5- Brake caliper
t removing:
450
Unscrew brake hose -Pos. 4- at brake caliper.
t Installing:
t repairing Chapter
one must first adjust the hand-brake after undertaking repair or replacement work, the foot
t
brake must not be applied beforehand!
6- Brake pads
t Thickness 17 mm (including the support plate)
t Wear limit: 7.5 mm (including supporting plate)
t Check thickness: BookletOctavia
7- Pad retaining spring
t always replace when changing the brake pads
8- Cover plate
9- 10 Nm
t tighten Chapter
11 - 4 Nm
12 - Brake disc, internally ventilated
t Diameter 256 mm
t Thickness 22 mm
t Wear limit 20 mm

451
13 - Brake disc
t Diameter 232 mm
t Thickness 9 mm
t Wear limit 7 mm
15 - Circlip
16 - Wheel bearing
17 - Trailing arm
t
20 - 8 Nm
21 - Drive shaft
Removing and installing brake pads
t Resetting tool -T10165-
t Assembly device -T10165/1-

452
Note
t
as otherwise this may cause uneven braking.
Removing

Raise vehicle.
Remove wheels.

453
Unscrew the fixing screws of the brake
carrier while counterholding the guide
bolts.
Note
The brake line and the surrounding

components are not shown to simplify the
illustration.

Remove the brake pads and pad
retaining springs -arrows-.
Note

housing.
Clean the brake caliper housing, in

particular the adhesive surface for the
brake pad must be free from glue
residues and grease.
Install
Note
Before inserting new brake pads, press the

piston with a resetting and turning out tool
-T10165- into the cylinder. Drain the brake
fluid from the brake fluid reservoir using a
ventilation bottle before pushing back.
to damage if brake fluid was added in the
meantime.
WARNING

454
Insert the resetting and turning out tool
-T10165- in such a way that the collar of
t
the tool -T10165/1- is resting on the
brake caliper.

t spanner surface -arrow A- if the piston is
difficult to move.
When adjusting the piston with a piston

resetting device the automatic
t
adjustment in the brake caliper is
destroyed.
Screw the piston by turning the knurled

the right into the brake caliper.
Insert the new pad retaining springs

-arrows- and brake pads in the brake
carrier.
supporting plate of the brake pad.
Note
There are four self-locking screws in the

repair set, which must be fitted.
Secure the brake caliper housing using
new self-locking screws.
Counterhold at the guide bolt when

tightening.
Tightening torque: 35 Nm.
455
-direction of the arrow- and hook on the

hand-brake cable -3-.
Fit clip -1-.
Attach the wheels.
Lower the vehicle.
Note
After each brake pad replacement,

t

t
brake pads.
Setting the hand-brake
resetting of the rear wheel-brake. New adjustment is only necessary when the handbrake
cable and brake carrier are replaced or after replacing the brake shoes.
Note
t The brake system must be bled and fully operational.
t Always replace self-locking adjusting nut.
456
1- Handbrake cable
Put the hand brake lever in its rest

position. Tighten adjusting nut so far that
the levers -arrow- rise from the stops on
the brake calipers.
457
Check the distance between the lever
and the stop on the left and right brake

caliper using feeler gauges.
The distance -a- between the lever and the

stop on the left and right brake caliper
must not be less than a minimum of 1 mm
or exceed a maximum of 3mm.
Pull the handbrake on and release it
three times. This will position and set the

components.
If the hand-brake lever is in its rest

position, check whether both wheels
rotate freely, if necessary release
adjusting nut slightly.
Remove and install hand-brake cable, four-wheel drive/disc brake
Removing

Raise vehicle.
458

Remove the rubber grommet -arrow A-
from the trailing arm.
Unhook the hand-brake cable out of the
bracket -arrow- and pull it out of the

trailing arm in -direction of arrow-.
Pull hand-brake cable -2- in -the direction
of the arrow- out of the guide tube -1-.
Install

order.
Note

459
Summary of Components of Foot Controls, Brake Pedal
Assembly overview of the foot controls, brake pedal - LHD vehicles
WARNING
The travel of the brake pedal must not be shortened by additional floor coverings.
Note
t Grease bearing and contact surfaces with grease -MoS2- (molykote grease).
When using a pedal with mechanical accelerator control, separate the accelerator control
t from the accelerator pedal before removing the mounting bracket Engine,
Mechanics; Rep. gr.20
1- Bearing bracket
t replace
t 4 pieces for securing the mounting bracket to the brake servo unit
t 2 pieces for securing the mounting bracket to the bulkhead

460
3- Brake light switch
before assembling the brake light switch, clip the brake pedal to the pressure rod of the
t
brake servo unit Chapter
t removing and installing, setting up to MY 1999 Chapter, as of MY 2000 Chapter
4- Accelerator pedal
t removing and installing: Engine, Mechanics; Rep. gr.20
6- Brake pedal
t separate from the brake servo unit Chapter
7- Cap
8- Screw
9- Bushing
10 - Bearing bolt
Assembly overview of the foot controls, brake pedal - RHD vehicles
WARNING
The travel of the brake pedal must not be shortened by additional floor coverings.
Note
t Grease bearing and contact surfaces with grease -MoS2- (molykote grease).
When using a pedal with mechanical accelerator control, separate the accelerator control
t from the accelerator pedal before removing the mounting bracket Engine,
461
1- Bearing bracket
t replace
462
t 4 pieces for securing the mounting bracket to the brake servo unit
t 1 pieces for securing the mounting bracket to the bulkhead
3- Brake light switch
before assembling the brake light switch, clip the brake pedal to the pressure rod of the
t
brake servo unit Chapter
t removing and installing, setting up to MY 1999 Chapter, as of MY 2000 Chapter
4- Screw
5- Brake pedal
separate from the brake servo unit Chapter
6- Cap
8- Bushing
9- Bearing bolt
10 - Strut
Separating the brake pedal from the brake servo unit and clipping
t Release tool -T10159A-
463
Release screws -2-.
Pull the footwell covering -1- out of the
holders.
Only for LHD vehicles
Release screws -1-.
Removing cover -A-.
On vehicles with manual gearbox,

remove the connecting plate between
the clutch pedal and the brake pedal
-arrows-.
Remove brake light switch -1- up to MY

1999 Chapter, as of MY 2000
Chapter.
Note
Fig. shows the separation of the brake

pedal from the brake servo unit with the
foot controls removed for clarity.
464
Press the brake pedal towards the brake
servo unit and hold it in position.
1- Brake pedal
2- Pressure rod
3- Retaining lugs
Insert release tool -T10159A- and pull

towards the driver's seat while
counterholding the brake pedal. (At this
moment the pedal must not move

backwards.) This causes the retaining
lugs -3- of the support to be pressed off
the spherical head of the push rod -2-.
Pull the release tool -T10159A- and the

brake pedal jointly towards the driver's
seat. (This causes the brake pedal to be

drawn off the ball knob of the pressure
rod).
Clipping the brake pedal onto the brake

servo unit
Hold the spherical head of the push rod in

front of the support and press the brake
pedal towards the brake servo unit until

the spherical head locks audibly into
place.
Installing and setting brake light switch
vehicles up to MY 1999 Chapter,

vehicles as of MY 2000 Chapter.
Tightening torques:
Connecting plate between clutch pedal and brake pedal 20 Nm
465
Removing and installing brake pedal
t Grease MoS2 (molykote grease)
Removing
Release screws -2-.
holders.
Only for LHD vehicles
Release screws -1-.
Take off cover -A-.
466
On vehicles with manual gearbox,
remove the connecting plate between
the clutch pedal and the brake pedal
-arrows-.
Unhook throttle control cable.
On vehicles with accelerator pedal
position sender, disconnect the plug

connection below the dash panel.
Removing brake light switch vehicles up
to MY 1999 Chapter, vehicles as of MY

2000 Chapter.
Separating the brake pedal from the
brake servo unit Chapter.
Remove all the fixing nuts of the foot
controls.
RHD vehicles
Remove the nut for the strut attached to

the mounting bracket and divert the
strut.
Remove foot controls.
Remove screwed connection of mounting
bracket - brake pedal.
Remove brake pedal.
Install
Note
Grease all bearing and contact surfaces

with grease MoS2.

order.

Tightening torques:
Brake pedal to bracket

467
Brake servo unit to mounting bracket 28 Nm
t Use new nuts!
Connecting plate between clutch pedal and brake pedal 20 Nm
468
Brakes, hydraulics, regulator, servo
Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles without ABS or
with ABS, ABS/EDL Mark 20
with ABS, ABS/EDL Mark 20 - LHD vehicles
Note
one another.
1- Brake servo unit without mechanical brake assistance
t all vehicles without ABS
t Vehicles with ABS, ABS/EDL up to and including model year 2001
- Brake servo unit with mechanical brake assistance
t Vehicles with ABS, ABS/EDL as of model year 2002
t mechanical brake assistance integrated in the brake servo unit
The brake assistance can only be recognized by the spare part number of the brake servo
t
unit
t The brake assistance cannot be repaired, replace the brake servo unit completely when
469
handling a fault Chapter
- Continued for all brake servo units
t check Chapter
t if there are faults replace completely
t separate from brake pedal Chapter
t on petrol engines the required negative pressure is drawn from the induction pipe
t vehicles using a diesel engine are fitted with a vacuum pump for generating a low pressure
t Non-return valve (in the vacuum hose of the vacuum pump)
Functional test
It must be possible to blow through the valve in the -direction of the arrow-.
Against the -direction of the arrow- the valve must be closed.
2- Screw cap
t locked with lateral catches in the retaining pin
4- Plugs
5- Retaining pin
two brake pressure senders (-G201- and -G214-) are additionally installed on vehicles with
t
ABS/EDL/ESP
t Check tightness Chapter
8- Heat shield
t replace
10 - Sealing ring
470
t replace
11 - Plugs
12 - Vacuum hose
13 - Gasket
t between brake servo unit and bulkhead
t replace
with ABS, ABS/EDL Mark 20 - RHD vehicles
Note
one another.
471
1- Brake servo unit with mechanical brake assistance
t all vehicles without ABS
t Right-hand drive vehicles with ABS, ABS/EDL
472
t mechanical brake assistance integrated in the brake servo unit
t
unit
The brake assistance cannot be repaired, replace the brake servo unit completely when
t
handling a fault Chapter
t check Chapter
2- Screw cap
t with lateral catches for locking screw
4- Plugs
5- Plugs
t moisten with brake fluid and press expansion reservoir into the sealing surfaces
8- Locking screw for brake fluid reservoir, 10 Nm
9- Sealing ring
t replace
10 - Gasket
473
t replace
replace
Removing and installing the master brake cylinder - LHD vehicles
t Hose clamp -MP 7-602-
t Repair set SP.-no. -1H0 698 311 A-
Note
t
coding.
After reconnecting the battery, a few additional operations must be carried out Electrical
t
System; Rep. gr.27
Removing
Disconnect battery Electrical System; Rep. gr.27.
Note

filter.
and lay it aside.
If necessary, remove the relay carrier

above the brake servo unit on diesel
engines.
474
Disconnect plug -1- from brake fluid level warning contact -F34-.
Using an extraction bottle extract as much brake fluid as possible from the brake fluid
reservoir.
Clamp off the running-on line of the clutch master cylinder -2- with hose clamp -MP 7-602-.
Disconnect the running-on line of the clutch master cylinder -2- from the brake fluid
reservoir -3- and tie up.
Unscrew the brake lines from the tandem master brake cylinder, close the brake lines with
the screw plugs from the repair kit SP no. -1 HO 698 311 A-.
Unscrew the heat shield on 74 kW, 92 kW and 110 kW engine.
Unscrew the tandem master brake cylinder from the brake servo unit.
Install
Replace the gasket ring between the master brake cylinder and the brake servo unit.
When installing the master brake cylinder with the brake servo unit pay attention to the
correct positioning of the pressure rod in the master brake cylinder.
Only fill up with new brake fluid after installing Chapter.
Connect battery Electrical System; Rep. gr.27.
Bleed clutch system (manual gearbox) Manual Gearbox; Rep. gr.30.
Repairing the clutch control BookletOctavia.
Initiate the basic setting on vehicles with EDL Chapter.
Removing and installing the master brake cylinder - RHD vehicles
Note
475
coding.
Removing
Vehicles with TDI turbocharger engines
Remove top charge air pipe with connecting hose Engine, Mechanics; Rep. gr.21.
Disconnect plug -3- from brake fluid level

Clamp off the running-on line of the

clutch master cylinder -4- with hose
clamp -MP 7-602-.
Disconnect the running-on line of the
clutch master cylinder -4- from the brake

fluid reservoir -2- and tie up.
Unscrew the brake lines from the tandem master brake cylinder -2- and -3-.
Shut-off brake lines with screw plugs from the repair kit SP No. -1 HO 698 311 A-.
Unscrew the tandem master brake cylinder from the brake servo unit.
Install
Replace the gasket ring between the master brake cylinder and the brake servo unit.
When installing the master brake cylinder with the brake servo unit pay attention to the
correct positioning of the pressure rod in the master brake cylinder.
Only fill up with new brake fluid after installing Chapter.
Connect battery Electrical System; Rep. gr.27.
Note
After reconnecting the battery, a few additional operations must be carried out Electrical
System; Rep. gr.27
Bleed clutch system (manual gearbox) Manual Gearbox; Rep. gr.30.
476
Repairing the clutch control BookletOctavia.
Initiate the basic setting on vehicles with EDL Chapter.
477
Check brake servo unit
Brake servo unit without brake assistance
Functional test
With the engine off press down brake pedal repeatedly with force (this reduces the pressure
already present in the device).
Now hold the brake pedal in brake position using a medium foot pressure and start the
engine.
If the brake servo unit operates perfectly the brake pedal must yield noticeably under your
foot (servo boost takes effect).
If there are any complaints, replace the brake servo unit.
Brake servo unit with mechanical brake assistance
Check the operation of the brake servo unit
Brake servo unit without brake assistance Chapter.
Check the operation of the brake assistance
With the engine running (full vacuum support must be guaranteed) forcefully apply the
brake pedal. While doing so, a "click" must be audible (the brake assistance is activated).
If no "click" is audible, then the brake assistance is defective and the brake servo unit must
be replaced completely.
When subsequently releasing the brake pedal, a considerably reduced force is exerted onto
the foot from the brake pedal when braking.
Removing and installing the brake servo unit - LHD vehicles
t Brake pedal load, e.g. -V.A.G 1238 B-
478
Note
coding.
Removing
Remove the hydraulic control unit Chapter.

clamp -MP 7-602-.

Remove vacuum hose from the brake
servo unit.
Release screws -2-.
holders.
479
Unscrew the nuts for brake servo unit
-arrows-.
The top right nut is not visible in the figure.
Guide the brake servo unit with master

brake cylinder towards the front and
remove.
Install
Install the brake servo unit with the
master brake cylinder and tighten the

new self-locking nuts to 28 Nm -arrows-.
Clip the brake pedal onto the brake servo
unit Chapter.

Fill up with new brake fluid Chapter.
System; Rep. gr.27.
out the coding.
Re-set clock.

BookletOctavia.
480
Bleed clutch system (manual gearbox)
Manual Gearbox; Rep. gr.30.
Repairing the clutch control
BookletOctavia.
Initiate the basic setting on vehicles with
EDL Chapter.
Removing and installing the brake servo unit - RHD vehicles
Note
coding.
Removing
Remove engine cover Engine, Mechanics; Rep. gr.10.
Remove induction pipe with exhaust gas recirculation valve and intake manifold Engine,
Lay sufficient non-fluffing cloths around the engine.
481
Remove master brake cylinder with brake fluid reservoir Chapter.
Release screws -2-.
holders.
Unscrew self-locking nuts for brake servo
unit -arrows-.
The top right self-locking nut is not visible

in the figure.
Slacken the brake servo unit towards the
front and remove.
Install
Install the brake servo unit and tighten
the new self-locking nuts -arrows-.
482
unit.

System; Rep. gr.27.
On vehicles with radio encoding, carry
out the coding.
Set clock.
Initialise power windows on vehicles

BookletOctavia.
BookletOctavia.
EDL Chapter.
483
Removing and installing the vacuum pump for the brake servo unit
Vehicles with diesel engine
Engine, Mechanics; Rep. gr.15
484
Repairing the front brake caliper, brake caliper FS III
Summary of Components of Brake Caliper FS-III
t Plastic wedge -3409-
Note
t Install the complete repair set when undertaklng repairs.
The brake calipers must absolutely be pre-bled before installing them in the vehicle
t (without brake pads) in case of a repair or when replacing them with new brake calipers
Chapter.
t Thinly coat brake cylinder, piston and gasket ring with brake fluid or assembly paste.
1- Dust cap
2- Vent valve, 10 Nm
t thinly coat thread with brake fluid or assembly paste before screwing in
3- Bushing
485
t insert into the brake caliper
5- Caps
t insert in bushing
6- Brake caliper
7- Sealing ring
8- Piston
t first thinly coat piston with assembly paste or brake fluid
9- Protective cap
t do not damage when inserting the piston
Removing and installing the front brake caliper piston
Removing
486
Press the piston out of the brake caliper
housing using compressed air -arrow-.
Note
Insert wooden plate so that the piston is

not damaged.
Take out gasket ring.

purpose.
Note
When removing, make sure that the

cylinder surface is not damaged.
Install
Clean the piston and gasket ring surfaces
with white spirits and dry off.
Before installing the piston and gasket

ring in the brake caliper housing, thinly
coat with brake fluid or assembly paste
-G 052 150 A2-.
Insert new gasket ring in the groove of
the brake caliper.
487
Position the new protective cap with the
outer sealing lip on the piston.
Insert the inner sealing lip of the
protective cap with a plastic wedge in the

groove of the cylinder.

purpose.
Note
To do so hold the piston in front of the

brake caliper housing.
Press the piston into the brake caliper

housing using the piston resetting jig -MP
9-403-.
Note
The outer sealing lip of the collar will

engage in the piston groove.
488
Repairing the front brake caliper, brake caliper FN 3
Assembly overview of the brake caliper FN3
Note
The brake calipers must absolutely be pre-bled before installing them in the vehicle
t (without brake pads) in case of a repair or when replacing them with new brake calipers
Chapter.
1- Cap
t insert in bushing
3- Bushing
489
t insert in brake caliper housing
4- Dust cap
t thinly coat thread with brake fluid or assembly paste before screwing in
6- Brake caliper
7- Brake carrier
t crewed to the brake caliper
8- Pad retaining spring
t insert with both ends into the bores in the brake caliper
9- Sealing ring
10 - Piston
t thinly coat with brake fluid or assembly paste before installing
t Piston diameter: 54 mm
11 - Protective cap
t do not damage when inserting the piston
t pull with outer sealing lip onto the piston
t insert with the inner sealing lip into the groove of the brake caliper Chapter
Removing and installing the front brake caliper piston
Removing
490
Press the piston out of the brake caliper
housing using compressed air -arrow-.
Note
Insert wooden plate so that the piston is

not damaged.
Take out gasket ring.

purpose.
Note
When removing, make sure that the

cylinder surface is not damaged.
Install

-G 052 150 A2-.
Insert new gasket ring in the groove of
the brake caliper.
491
protective cap with a plastic wedge in the

groove of the cylinder.

purpose.
Note
To do so hold the piston in front of the

brake caliper housing.
Press the piston into the brake caliper

housing using the piston resetting jig -MP
9-403-.
Note
The outer sealing lip of the protective cap

will engage in the piston groove.
492
Repairing the rear brake caliper
Summary of components of the brake caliper
Note
The brake calipers must absolutely be pre-filled with brake fluid before installing them in
t the vehicle (without brake pads) in case of a repair or when replacing them with new brake
calipers Chapter.
t replace
t counterhold on the guide bolt when releasing and tightening

493
t thinly coat thread with brake fluid or assembly paste before screwing in -G 052 150 A2-
3- Dust cap
4- Guide bolt
t grease before fitting protective cap
5- Protective cap
t pull onto brake carrier and guide bolt
6- Brake carrier with guide bolts and protective caps
if there is any damage to the protective caps or guide bolts fit a repair set (use the enclosed
t
grease packing to lubricate the guide bolts)
7- Protective cap
t pull with outer sealing lip onto the piston
t insert with the inner sealing lip into the groove of the brake caliper housing Chapter
8- Piston with automatic adjusting device
t thinly coat piston with brake fluid or assembly paste before installing -G 052 150 A2-
9- Sealing ring
t take out with a plastic wedge Chapter
10 - Brake caliper housing with lever for the handbrake cable
t replace brake caliper housing if the lever for the handbrake cable is not sealed
t pre-bleed brake caliper housing after undertaking repairs Chapter
Removing and installing the rear brake caliper piston
Removing:
494
Insert the resetting tool -T10165- in such
a way that the collar of the resetting tool

is resting on the piston.
Release the piston by turning the knurled

the left.

spanner surface -A- if the piston is difficult
to move.
Note
Make sure that the cylinder surface is not

damaged when removing the gasket ring.
Take out gasket ring with plastic wedge
-3409-.
Installing:

-G 052 150 A2-.
Insert new gasket ring in the brake
caliper.

protective cap with a plastic wedge
495
-3409- in the groove of the cylinder.
To do so hold the piston with the hand.
Insert resetting tool -T10165-.
To insert use the special tool -T10165/1-.
Screw in piston by turning the knurled
wheel to the right.

spanner surface -A- if the piston is
difficult to move.
Note
When resetting the piston with a

t resetting tool the automatic piston
setting in the brake caliper is destroyed.
It is absolutely necessary, if repairs are

being undertaken, to bleed the brake
t
calipers before installing them in the
vehicle (without brake pads).
Insert brake pads.
Temporary filling of brake caliper
Note
The brake caliper must be positioned vertically for pre-bleeding.
Open vent valve -arrow A-.

Filling up -arrow B- (brake hose connection).
Close vent valve.
496
Summary of components of brake-power regulator
1- Brake-power regulator
t testing and adjusting Chapter
2- Brake line with pipe screw
t Tightening torque of the pipe screw 14 Nm
3- Oval-head countersunk screw, 21 Nm
5- Tension spring
6- 16 Nm
7- Socket nut
8- Screw
Inspecting and adjusting the brake-power regulator

497
t Brake-power regulator or brake system tester, e. g. -V.A.G 1310- or -V.A.G 1310 A-
The brake-power regulator is secured to a

bracket assigned to the mount for rear axle
and is controlled by the rear axle
movement via a spring.
Functional test
Forcefully apply the brake pedal and

release quickly (vehicle is standing on its
wheels). While doing so the lever of the
brake-power regulator must move.
Pressure test and adjustment
Note
The brake-power regulator is adjusted on a

vehicle with unladen weight.
Unladen weight refers to: The weight of an

unladen vehicle (fuel tank empty up to
max. 5 litres, without driver, with spare
wheel, tool kit, jack).
498
Raise vehicle and
connect pressure
gauge to the brake
caliper (left front

wheel) and to the
wheel-brake cylinder
(right rear wheel).
Bleed both pressure
gauges.
Lower vehicle and

repeatedly depress
vehicle and allow to

settle on the rear
axle.
Press brake pedal
and measure
pressures.
Compare measured
pressure values to
the specified
adjusting values
Chapter.
If necessary adjust
brake-power
regulator Chapter.
499
Adjusting values for the load-dependent brake-power regulator
Model/Version bar MPa bar MPa
Drum brakes on the Front axle 70 7 Front axle 100 10
Rear axle Rear axle 41 ... 47 4,1 ... 4,7 Rear axle 54 ... 60 5,4 ... 6,0
Adjusting brake-power regulator
Test pressure on rear axle too high:
Release tension spring on brake-power regulator.
Test pressure on rear axle too low:
Tighten tension spring on brake-power regulator.
Note
Adjust without load on the brake pedal, observe the following sequence:
Read off values.
Release brake pedal.
Adjust tension spring on brake-power regulator.
Again load brake pedal.
Read-off values and if necessary correct adjustment.
Remove pressure gauge.
Bleed brake system, vehicles with or without ABS or ABS/EDL Mark 20 and Mark 60
t Vehicle system tester -V.A.G 1552- (only for vehicles with ABS/EDL)
Note
t Only use new brake fluid complying with the standard Chapter.
t If the system is opened, avoid working with compressed air and avoid moving the vehicle.
500
Bleeding the brake system is described using the brake filling and bleeding device, e.g.
t
-VAS 5234-.
If one chamber of the brake fluid reservoir has run completely dry, e.g. leakage in the brake
system, bleeding must be carried out using the brake filling and bleeding device, e.g. -VAS
5234-. Then the hydraulic unit is tested with the vehicle system tester -V.A.G 1552- in the
function "basic setting" or with the vehicle diagnosis, measurement and information system
-VAS 505x-.
Note
Only use new brake fluid Chapter.
WARNING
Brake fluid is hygroscopic, i.e. it retains humidity from the ambient air, and must therefore
t
always be stored in airtight containers.
Brake fluid must never come into contact with fluids containing mineral oils (oil, petrol,
t
cleaning agent). Mineral oils damage the plugs and boots of the brake system.
t Drained (used) brake fluid must never be used again.
t Observe the disposal instructions!
t Brake fluid is toxic, avoid skin contact.
t Because of its caustic effect brake fluid must not come into contact with paint.
t Rinse any brake fluid spills with a lot of water.
t Dispose of brake fluid in compliance with the applicable environmental regulations.
Vehicles without ABS or ABS/EDL
Connect up the brake filling and bleeding device e.g. -VAS 5234- but do not yet switch it
on.
Bleeding sequence Chapter
Remove dust caps from the vent valves of the brake calipers/wheel-brake cylinder.
Switch on brake filling and bleeding device e.g. -VAS 5234-.
Leave the bleeder screws on the plugged-on hose of the bleeder bottle open for as long as
is takes until the bubble-free brake fluid flows out.
Vehicles with Mark 20 or Mark 60
Connect up the brake filling and bleeding device e.g. -VAS 5234- but do not yet switch it
on.
If one chamber of the brake fluid reservoir has run completely dry (e.g. leakage in the brake
system) first of all a pre-bleeding of the brake system must be performed.
501
Bleeding sequence for vehicles with Mark 20 Chapter
Bleeding sequence for vehicles with Mark 60 Chapter
Then bleed the hydraulic unit with the function Basic setting and the vehicle system tester
-V.A.G 1552-.
A characteristic feature of right-hand drive vehicles
If one chamber of the brake fluid reservoir

has run completely dry (e.g. leakage in the
brake system) or after changing the
hydraulic unit, then the master brake
cylinder must be bled via the bleeder
valves after carrying out the basic setting
-arrows-.
Continued for vehicles with Mark 60
Perform a null balance for the brake

pressure sender -1--G201- after bleeding
the brake system Chapter.
When replenishing brake fluid with a brake

filling and bleeding device, it is important
to ensure that the filling pressure of 0.1
MPa (1 bar) is not exceeded.
Therefore the brake fluid pressure on the

brake filling and bleeding device must be
regulated down to 0.1 MPa (1 bar)
Operating instructions of the bleeding
device
If the filling pressure of 0.1 MPa (1 bar) is

exceeded, proper bleeding of the hydraulic
unit is no longer assured.
Mark 20 Chapter.
Mark 60 Chapter.
After bleeding perform a test drive. While

doing so perform at least one ABS
adjustment!
502
Bleeding brake system with brake filling and bleeding device for vehicles with Mark 20
t Vehicle system tester -V.A.G 1552- (only for vehicles with ABS/EDL)
Opening the bleeder screws on the hydraulic unit is not allowed on vehicles with ABS,
ABS/EDL!
Connect up the brake filling and bleeding device, e.g. -VAS 5234-, but do not yet switch it
on.
Remove dust caps from the bleeder screws of the brake calipers/wheel-brake cylinders.
Open the bleed valves in the prescribed sequence with the hose of the bleeding bottle
fitted, switch on the brake filling and bleeding device and bleed both the brake calipers and
the wheel-brake cylinders.
Bleeding sequence
1- Rear right wheel-brake cylinder/brake caliper
2- Rear left wheel-brake cylinder/brake caliper
3- Front right brake caliper
4- Front left brake caliper
After bleeding close the relevant bleeder screw and fit dust cap.
Switch off the brake filling and bleeding device.
Remove the connection on the brake fluid reservoir.
Vehicles with ABS or with ABS/EDL
A road test must be carried out with these vehicles after bleeding. While doing so perform at
least one ABS adjustment!
Note
For vehicles with brake-power regulator move the rear wheel-brake lever of the regulator
during bleeding.
Change brake fluid BookletOctavia
503
Bleeding the brake system without using the brake filling and bleeding device
Opening the bleeder screws on the hydraulic unit is not allowed on vehicles with ABS,
ABS/EDL!
Note
While bleeding continuously check the brake fluid level in the brake fluid reservoir. If
necessary, top up brake fluid up to the MAX marking.
Open the bleeder screw with the hose of the bleeding bottle fitted.
Flush the brake fluid through the brake system by pumping the brake pedal.
Close the vent valve with the pedal pressed down.
Proceed pumping with the pedal at least 10x per wheel brake and repeat the procedure
until no more air escapes.
Bleeding sequence for vehicles with Mark 20
1- Rear right wheel-brake cylinder/brake caliper
2- Rear left wheel-brake cylinder/brake caliper
Bleeding sequence for vehicles with Mark 60
3- Rear left brake caliper
4- Rear right brake caliper
Vehicles with ABS or with ABS/EDL
A road test must be carried out with these vehicles after bleeding. While doing so perform at
least one ABS adjustment!
Note
For vehicles with brake-power regulator move the rear wheel-brake lever of the regulator
during bleeding.
Change brake fluid BookletOctavia
504
505
Bleeding brake system with brake filling and bleeding device for vehicles with ABS Mark 60

Connect up the brake filling and bleeding device, but do not yet switch it on.
Open the bleed valves in the prescribed sequence with the hose of the bleeding bottle fitted, switch on the
brake filling and bleeding device and bleed both the brake calipers and the wheel-brake cylinders.
Bleeding sequence
3- Rear left brake caliper
4- Rear right brake caliper
After bleeding the relevant valve, close the vent valve and fit on the dust cap.
After bleeding perform a test drive. While doing so perform at least one ABS adjustment!
Pre-bleed the brake system if one chamber of the brake fluid reservoir has run completely empty (e.g.
leakage in the brake system).
Bleeding sequence
1- Bleed the front left and front right brake caliper simultaneously
2- Bleed the rear left and rear right brake caliper simultaneously
Leave the bleeder screws on the plugged-on hose of the bleeder bottle open for as long as is takes until
the bubble-free brake fluid flows out.
Checking the master brake cylinder for tightness
t Brake-power regulator or brake system tester, e. g. -V.A.G 1310- or -V.A.G 1310 A-
Test condition
l Function and tightness of the brake system O.K.
The brake system includes:
t Hydraulic control unit or load-dependent brake-power regulator
t Brake lines, brake hoses and their connections
t Brake calipers and wheel-brake cylinder
Test
Release the bleeder screw on one of the front brake calipers.
506
Connect the
pressure gauge of
the tester -V.A.G

1310- or -V.A.G 1310
A- and bleed.
Push down brake

pedal until the
pressure gauge on
the tester indicates
an overpressure of 5
MPa (50 bar).
Test duration 45
seconds.
The pressure loss

must not exceed
0.40 MPa (4 bar)
throughout the test.
If the pressure loss

exceeds 0.40 MPa (4
bar) replace the
master brake cylinder.
LHD vehicles
Chapter.
RHD vehicles
Chapter.
Repeat the test after
replacing the master

brake cylinder.
Separate the
pressure gauge of
the tester -V.A.G
1310- or -V.A.G 1310
A- from the brake
caliper.
Thinly coat the

thread of the vent
valve with brake
fluid or assembly
paste -G052 150
A2-.
Screw the vent valve
into the brake

caliper and tighten.
Tightening torque: 10
507
Nm
Bleeding Brake
System
Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles with
ABS/EDL/ESP Mark 20
Note
one another.
1- Brake servo unit
t check Chapter

508
Functional test
Against the direction of the arrow the valve must be closed.
t replace
3- Gasket
4- Bellows
t pay attention to correct position, risk of suction noises
5- Holder
t is attached to the edge of the brake servo unit
t serves for the support of the plug -Pos. 18-
6- Screw cap
8- Sealing ring
t replace
t for fixing the wiring loom -Pos. 16-
10 - Plugs
11 - Retaining pin
509
12 - Master brake cylinder
13 - Self-locking nut 20 Nm
t replace
14 - Heat shield
t in the floating piston circuit
16 - Wiring loom
t in the push rod piston circuit
18 - Connector
t Connection wiring loom dash panel/engine compartment
19 - Plugs
20 - Vacuum hose
Removing and installing brake pressure sender -1--G201- and brake pressure sender -2--
G214-
Note
t Before disconnecting the battery determine the code of radio sets fitted with anti-theft
510
coding.
re-set clock
Removing
Disconnect battery.

filter.
and lay it aside.
Lay sufficient non-fluffing cloths around

the plenum chamber, the engine and the
gearbox.

Attach the hose of the bleeding bottle
onto the bleeder screw of the front left

brake caliper and open the bleeder screw.
Depress the brake pedal at least 15 times

so that the master brake cylinder runs
empty.
Close the front left bleeder screw while
the pedal is pressed down.
511
Disconnect the plug -arrow- of the
relevant brake pressure sender to be
removed.
Brake pressure sender -2--G214- in the

2-
floating piston circuit
Brake pressure sender -1--G202- in the

3-
push rod piston circuit
Remove brake pressure sender -1--G202-
or brake pressure sender -2--G214-.
Install

order.
System; Rep. gr.27.
Only fill up with new brake fluid after
installing.
Perform basic setting of brake pressure
sender -G202- and -G214- Chapter.
Tightening torques:
Brake pressure sender -1- 25 Nm
Brake pressure sender -2- 25 Nm
Removing and installing the master brake cylinder - LHD vehicles
t Repair set SP.-no. -1 HO 698 311 A-
512
Note
t
coding.
set clock,
Removing
Disconnect battery.

filter.

gearbox.

brake fluid reservoir -5-.

clamp -MP 7-602-.

4- Heat shield
513
Disconnect the plug -arrows- of the brake
pressure sender -2- and -3-.
Release the nuts of the master brake
cylinder -1-.
If present, remove the heat shield.
Carefully remove the master brake
cylinder -1- from the brake servo unit.
Install

order.
Replace the gasket ring between the

master brake cylinder and the brake
servo unit.
When installing the master brake cylinder

with the brake servo unit pay attention to
the correct positioning of the pressure
rod in the master brake cylinder.
installing.
System; Rep. gr.27.
Tightening torque:
Master brake cylinder to brake servo unit 20 Nm
Removing and installing the master brake cylinder - RHD vehicles
514
Note
coding.
Removing


clamp -MP 7-602-.

Disconnect the plug of the brake
pressure sender -arrows-.
515
Unscrew the brake lines from the tandem
master brake cylinder -2- and -3-.
Shut-off brake lines with screw plugs

from the repair kit SP No. -1 HO 698 311
A-.
Unscrew the tandem master brake
cylinder from the brake servo unit.
Install

order.
Replace the gasket ring between the

master brake cylinder and the brake
servo unit.
When installing the master brake cylinder

with the brake servo unit pay attention to
the correct positioning of the pressure
rod in the master brake cylinder.
installing Chapter.
System; Rep. gr.27.
Note
After reconnecting the battery, a few

additional operations must be carried out
BookletOctavia.
EDL Chapter.
516
Chapter
Removing and installing the brake servo unit - LHD vehicles
t Brake pedal load, e.g. -V.A.G 1238 B- or -V.A.G 1869/2-
t Release tool -T 10159 A-
t Repair kit -1 HO 698 311 A-
Note
t
coding.
t After connecting the battery check the vehicle equipment:
set clock,
Removing
Disconnect battery.
517
filter.
and lay it aside.

gearbox.
Remove hydraulic control unit -1-
Chapter.

clamp -MP 7-602-.

Detach the vacuum hose -2- from the
brake servo unit.
Press the plug connection -1- out of the
holder -3-.
To do so, press the plug connection -1- in

the direction of the bulkhead.
2- Brake servo unit
Disconnect plug connection -1-.
518
Release screws -2-.
holders.
Unscrew the nuts for brake servo unit
-arrows-.
The top right nut is not visible in the figure.
Guide the brake servo unit with master

brake cylinder towards the front and
remove.
Install
Install the brake servo unit with the
master brake cylinder and tighten the

new nuts -arrows-.
519
unit Chapter.

System; Rep. gr.27.
Tightening torque:
Brake servo unit to foot controls 28 Nm
Removing and installing the brake servo unit - RHD vehicles
Note
520
coding.
Removing
Remove engine cover Engine, Mechanics; Rep. gr.10.
Remove induction pipe with exhaust gas recirculation valve and intake manifold Engine,
Lay sufficient non-fluffing cloths around the engine.
Remove master brake cylinder with brake fluid reservoir Chapter.
Release screws -2-.
holders.
Unscrew self-locking nuts for brake servo
unit -arrows-.
The top right self-locking nut is not visible

in the figure.
Slacken the brake servo unit towards the
front and remove.
Install
521
Install the brake servo unit and tighten
the new self-locking nuts -arrows-.
unit.

System; Rep. gr.27.
On vehicles with radio encoding, carry
out the coding.
Set clock.
Initialise power windows on vehicles

BookletOctavia.
BookletOctavia.
EDL Chapter.
522
Removing and installing the vacuum pump for the brake servo unit
Vehicles with diesel engine
Engine, Mechanics ; Rep. gr.15
Summary of components: Brake Servo Unit/Master Brake Cylinder for vehicles with
ABS/EDL/TCS/ESP Mark 60
Note
one another.
1- Brake servo unit without mechanical brake assistance
t Right-hand drive vehicles with ABS/EDL/TCS/ESP Mark 60
t Left-hand drive vehicles with ABS/EDL/TCS/ESP Mark 60 up to and including model year
523
2001
t Left-hand drive vehicles with ABS/EDL/TCS/ESP Mark 60 as of model year 2002
t
unit
The brake assistance cannot be repaired, replace the brake servo unit completely when
t
handling a fault LHD vehicles Chapter, RHD vehicles Chapter
t check Chapter
t removing and installing LHD vehicles Chapter, RHD vehicles Chapter
the electric brake vacuum pump is additionally installed on vehicles with automatic gearbox
t
and in combination with EU4 -V192-
t -V192- check operation Chapter
t Remove and install the brake vacuum pump -V192- Chapter
Functional test
Against the direction of the arrow the valve must be closed.
2- Screw cap
3- Brake fluid reservoir, left-hand drive
4- Plugs
t moistened with brake fluid, press in expansion reservoir
5- Retaining pin
524
t serves to fix the wiring loom
t always replace
9- Heat shield
t only for vehicles with 74 kW, 92 kW, 110 kW and 132 kW engine
11 - Sealing ring
t always replace
12 - Plugs
t Connection for vacuum hose
13 - Gasket
t always replace
14 - Self-locking nut 20 Nm
525
Removing and installing brake pressure sender -1--G201-
When using the hydraulic control unit Mark 60, the master brake cylinder has only one brake
pressure sender.
Removing and installing master brake cylinder
LHD vehicles Chapter.
RHD vehicles Chapter.
Chapter.
Removing and installing brake servo unit
LHD vehicles Chapter.
RHD vehicles Chapter.
Removing and installing brake vacuum pump -V192-
No provision is made for repairing the brake vacuum pump -V192-. The brake vacuum pump -V192- must
be replaced if a fault arises.
The fitting location of the brake vacuum pump -V192- can be found on the bottom left of the assembly
carrier
Removing
Unscrew the screws -1- at the bracket for the
brake vacuum pump -V192-.

Remove the vacuum hose -arrow- from the
brake vacuum pump -V192-.

Take out the brake vacuum pump -V192-.
Unlock the plug connection and remove it from
the brake vacuum pump.
526
Bracket -arrow- for the brake vacuum pump
-V192-.
Unscrew the counternut -2- from the screw -1-.
Release screw -4-.
Remove bracket.
Unscrew the screws -3- for further disassembly
of the bracket -arrow-.

Install
Tightening torques:
Nut -2- to bracket 20 Nm
Screws -3- to bracket 8 Nm
Screw -4- to bracket 20 Nm
Inner Torx screw for brake vacuum pump -V192- to bracket 8 Nm
Testing brake vacuum pump -V192-
During the start operation, the brake vacuum pump must start -V192- running briefly.
Work procedure
Run the vehicle on the lift platform, switch off engine.
Start engine.
A second person must check the operation of the brake vacuum pump by touching it with
the hand -V192-.
If the brake vacuum pump -V192- does not run:
Interrogate the fault memory of the engine control unit Engine, Fuel Injection and Ignition
System; Rep. gr.01.
527
Steering
Steering column and steering wheel with airbag
Check the steering column for damage

t Locking pin -T10060A-
Visual inspection
Check the steering column for damage.
If any damage is visible, replace steering column completely.
Test condition
l Universal joint of steering column pulled off steering gear
Functional test
Check whether the steering column turns freely without jerking.
Check whether the length and height of the steering column can be adjusted.
In the event of an accident so-called deformation elements may shift on the steering column.
They are located on the two top bolted connections of the steering column.
If there is any damage remove the steering column until dimension -a- can be checked.
Insert locating pin -T10060A-.

Inspect dimension -a- with a sliding caliper.
Dimension -a-: maximum 23 mm
If a fault is found during one of these inspections,
then the steering column must be replaced.
If this is the case replace the steering column
completely.
Removing and installing steering column
Note
New steering columns supplied as spare parts are secured for transport. This transport
t
security must be removed once the steering column has been installed.
The steering column is supplied as a spare part with ignition lock housing but without lock
t
cylinder and ignition starter switch.
t The ignition lock housing can be modified.
t Remove and install ignition lock housing Anchor.
t It can happen that on new steering columns, which are supplied as spare parts, the lock
528
cylinder and the ignition starter switch from the old steering column must be refitted or
must be obtained as a spare part and installed Electrical System; Rep. gr.94.
t Repairing the steering column is not possible.
t Replace the self-locking nuts and screws.
t Welding and straightening of the steering components is not allowed.
t
coding.
set clock,
Removing
Disconnect battery.
Put the wheels in straight-ahead position.
Release screws -2-.
holders.
Remove the airbag on the driver's side
Remove steering wheel Body
Work; Rep. gr.69.
Unclip cover for fuse carrier.
529
Remove light switch -3- Electrical
System; Rep. gr.96.
Remove screws -5- for fuse carrier.
Remove bottom part of dash panel -4-.
Unscrew screws -1-, -2-, -3- and -4-.
Remove the top and bottom part of the
steering column trim panel.
530
The figure shows the coil spring -4- on a
vehicle without Electronic Stability Program
(ESP).

adhesive tape -3-.
Unplug connector -1-.
Carefully remove all the plug connections
from the steering column switch -2-.
-Arrows- Catch hook of coil spring -4-
Note
The following working step is only

t required when replacing the coil spring or
the steering column switch.
The coil spring must be removed and

t installed when it is in the centre position
(wheel in straightahead position).
The coil spring is secured as a spare part

t
in the centre position with a cable strap.
Release catch hook -arrows- and remove

coil spring -4- from steering column
switch -2-.
Note
If the coil spring remains on the steering

column switch, ensure that the coil spring
does not turn out of the centre position
when placing down the steering column
switch.
Vehicles with ESP
Vehicles with ESP are additionally fitted

with the steering angle sender -G85-. It is
fitted together with the coil spring in the
housing.
The description of the basis, construction

and function of the ESP can be found in
self-study programme No. 28.
- Check whether the front wheels are in the

straight-ahead position.
531
If necessary, fit on the steering wheel
and put the front wheels in a straight

ahead position.
Remove steering wheel.
Note
The following two work steps must only be

performed when reinstalling at a later
stage the same housing with a coil spring.
centre position:

-1-.
The markings -arrows- must be flush.

adhesive tape -1-. -3- Housing
532
Disconnect plug -1- from housing.
Carefully release catch hooks -arrows-
and remove housing -1- with steering

angle sender -G85- and coil spring.
Slacken the screw of the steering column
switch -arrow- until the steering column

switch can be slightly moved.
Remove steering column switch.
Disconnect plugs -1- and -2-
LHD vehicles
533
Unscrew plastic nuts -1- and remove
cover -A-.
RHD vehicles
Unscrew plastic screw -1-, remove plastic
bushing, screw out plastic nut -2- and

remove cover -A-.
Release screw -1-.
02.97 if a clamping ring is installed.
Slacken the Allan screw of the clamping

ring -2- so far until the universal joint can
be removed from the steering gear
pinion.
Remove the universal joint from the
steering gear pinion -arrow-.
Note
An assembly securing device is required

to prevent the lower and the upper part
t
of the steering column from separating
during removal of the steering gear.
t If the upper and the lower parts of the

steering column are separated too widely
534
or are pushed into one another then the
gearing system will become separated.
This could cause rattling noises during
operation at a later stage if the gear
teeth are no longer in their original
installed position.
Secure the steering column before
removal.
Push together or pull apart the steering
column until the hole is visible.
For example, fit a clip into the hole
-arrow- in order to secure the position.
LHD vehicles
Unscrew the self-locking nut -1- at the
central pipe and pull out the screw -2-.
RHD vehicles
535
Release the self-locking nut -2- and pull
out the screw -1-.
Release screws -arrows-.
Remove steering column.
Note
New steering columns are generally

t
supplied with ignition lock housings.
Ignition lock housings are supplied

t
individually as a spare part.
Replace ignition lock housing
Remove ignition lock housing Electrical
System; Rep. gr.94.
Bore out pull-off screws -arrows-.
Tighten pull-off screws -arrows- until the
head shears off.
Install ignition lock housing Electrical
system; Rep. gr.94.
Install
Note
New steering columns supplied as spare

t
parts are secured for transport.
This transport security must be removed

t once the steering column has been
installed.
t It can happen that on new steering

columns, which are supplied as spare
536
parts, a new bushing and pull-off screw
must be fitted before installing the
steering column.
The pull-off screws and the bushing must

t be replaced after each disassembly of the
bushing.
Insert new bushing -1- and install pull-off
screw -2-.
Tighten pull-off screw -2- until the head
shears off.
LHD vehicles
Position steering column to central pipe.
Screw in screws -3-, but do not tighten.
Insert new screw -2-.
Screw on new self-locking nut -1- and
tighten to 10 Nm.
RHD vehicles
537
Position steering column to central pipe.
Screw in screws -3-, but do not tighten.
Insert new screw -1-.
Screw on new self-locking nut -2- and
tighten to 10 Nm.
Tighten screw -3- to 22 Nm.
Pull out transport security -arrow-.
Slide the universal joint onto the steering
pinion and tighten with new screw -1-.
Tighten the Allan screw of the clamping
ring -2- to 17 Nm.
Fit cover for universal joint.
Mount plug for ignition starter lock and
immobiliser.
Slide the steering column switch onto the
steering column.
Vehicles without ESP
Slide the coil spring onto the steering
column and lock into position with the

steering column switch.
Vehicles with ESP
538
Slide housing -1- with steering angle
sender -G85- and coil spring onto the
steering column and lock into position
with steering column switch -arrows-.
Mount plug at housing -1-.
Note
After removing the transport protection or

the adhesive tape do not turn the coil
spring, only the positioning of the steering
angle sender -G85- in centre position is
allowed.
After installing a housing -1- remove
transport protection -2-.
After installing a used housing -3-
remove adhesive tape -1-.
-2- Coil spring
539
Position the steering angle sender -G85-
in the centre position:

-1-.
Markings -arrows- must be flush with each

other.
Make sure this correct position is

maintained.
The further work procedure is now valid

again for all vehicles.
Fit the steering wheel onto the steering
column and screw in the old internal

serration screw and tighten.
Note
The fig. shows the steering column switch

t with coil spring -2- and steering wheel -1-
on a vehicle without ESP.
On vehicles with ESP, the dimension a

between the coil spring integrated in the
t
housing and the steering wheel is also 3
mm.
Align the steering column switch so that it

is horizontal and set dimension a,
subsequently tighten the clamping screw
-3-.
Demount the steering wheel again.
540
Mount plug -1-.
Fit together the plug connections on the
steering column switch.
Note
After removing the adhesive tape -3-, do

not turn the coil spring out of its centre
position.
Carefully remove the adhesive tape -3-.
Installing the trim panel for steering
column switch Body Work; Rep. gr.70.
Installing the lower part of the dash
Install footwell covering on driver's side
Install steering wheel Body work; Rep.
gr.69.
Install the airbag on the driver's side
WARNING
Nobody should be in the vehicle when the

battery is being connected!
System; Rep. gr.27.
Vehicles without ESP:
Vehicles with ESP:
angle sender Chapter.
Removing and installing the ignition lock housing with the steering column mounted
541
Note
t
coding.
re-set clock
Removing
Remove steering wheel Body Work; Rep. gr.69.
Remove bottom part of dash panel Body Work; Rep. gr.70.
Removing trim panel for steering column switch Body Work; Rep. gr.70.
Disconnect plug -1- for ignition starter
lock and plug -2- for immobiliser.
Removing lock cylinder and ignition

starter switch Electrical System; Rep.
gr.94.
Removing steering-column control
Removing dash panel insert Electrical
System; Rep. gr.90.
Bore out pull-off screws -arrows- and take
out ignition lock housing.
Install
Insert the ignition lock housing and
tighten with new pull-off screws.
Tighten pull-off screws until the head
shears off.
Installing lock cylinder and ignition

starter switch Electrical System; Rep.
gr.94
Installing dash panel insert Electrical
System; Rep. gr.90
Mount plug for ignition starter lock and

542
immobiliser.
Align the steering column switch to the
steering column and tighten Chapter.
Install the trim panel for steering column
switch and the bottom part of the dash

panel Body Work; Rep. gr.70
Install the steering wheel and the airbag

on the driver's side Body Work; Rep.
gr.69
WARNING
Nobody should be in the vehicle when the

battery is being connected!
System; Rep. gr.27.
Vehicles without ESP
Vehicles with ESP
angle sender -G85- Chapter.
543
Summary of components of power-steering gear - LHD vehicles
Note
If the front axle is damaged as a result of an accident certain steering components must be
t
replaced Chapter.
No provision is made for repairing on the power-steering gear. If there are any complaints
t
about the steering gear, replace it.
Only use semi-fluid gear lubricant AOF 063 000 04 to grease the gear rack (filling capacity
t
23 to 27 g).
t Oil type: hydraulic oil -G 002 000-
t Oil quantity in the system: 0.7 ... 0.9 Itr.
544
1- Heat shield
t centre with mounting bracket on the power-steering gear
2- Nut, 23 Nm
3- Bearing bracket
t only on gearbox 02K
4- 23 Nm
5- Steering column universal joint
6- 20 Nm + 90
7- Sealing sleeve
t Pay attention to installation instructions Anchor
8- Return-flow line
t from the power-steering gear to the reservoir for central hydraulic oil
t the distance to the power-steering gear must be 10 mm
9- Gasket rings
10 - Hollow screw, 45 Nm
t M16 x 1.5
t M14 x 1.5
12 - Pressure line (expansion hose)
t from the vane pump to the power-steering gear
13 - Counternut, 50 Nm
14 - Steering-knuckle arm of the wheel-bearing housing
16 - 100 Nm + 90
17 - 100 Nm + 90
18 - 20 Nm + 90
545
19 - Pendulum support
20 - 40 Nm + 90
21 - 20 Nm + 90
22 - 20 Nm + 90
24 - Retaining clip
25 - Nut, 23 Nm
26 - Clamp with rubber insert
Fitting position:
t Arrow on the clamp points in the direction of travel
t replace the clamp if the thread of the weld nut is damaged
27 - Power-steering gear
t adjust Chapter
Removing and installing hydraulic oil reservoir
t Pliers for spring strap clamps
t Hydraulic oil -TL 52 146-, -N 052 146 00- e.g. -PENTOSIN CHF 11 S (G 002 000)-
546
1- Reservoir with screw cap and oil dipstick
t Tighten screw cap to 2 Nm
t Check the level of hydraulic oil, top up if necessary Chapter
2- Return-flow line
t The longitudinal markings -A- must be flush
t Fit the spring strap clamp onto the hose as far as the lateral marking -B-
3- Spring strap clamp
t to open and close use pliers for spring strap clamps
t The tensioning eyes must face to the top
4- Suction line
5- 10 Nm
Removing and installing the power-steering gear - LHD vehicles

547
t Extractor Matra -V 176-
t Plug for hydraulic oil reservoir (commercially available)
Plastic screw plugs for line connections on the power-assisted steering gear (commercially
t
available)
Note
Apart from replacing the bellows and the track rods, no provision is made for further
t
repairs.
t Absolute cleanliness is required when working on the power steering.
t Thoroughly clean the connection points and their surroundings before releasing.
Place removed parts on a clean surface and cover if the repair cannot be carried out
t
immediately.
t Do not use drained hydraulic oil again.
t Replace gasket rings.
t Disposal Chapter.
Removing
548
Unscrew plastic nuts -1- and remove
cover -A-.
Release screw -1-.
WARNING
Bring the steering wheel in its central

position (with the wheels straight ahead)
and make sure that it does not turn during
repairs as this could damage the coil
spring of the airbag unit.
Slacken the Allan screw of the clamping

ring -2- so far until the universal joint can
be removed from the steering gear
pinion.
Pinch off the suction line -1- (hydraulic oil
reservoir/vane pump) with the hose

clamp -MP 7-602- near the vane pump.
The fig. shows the line routing and how to

pinch off the line on the 1.9 ltr./66 kW TDI
engine. For the other engine versions, the
suction line routing is modified. The suction
line must, however, be pinched off near the
vane pump.
549
Open spring strap clamps -arrow- with
pliers for spring strap clamps.
Release the return-flow line from the

hydraulic oil reservoir and allow the
hydraulic oil to flow out into a suitable
vessel.
Close the return-flow opening at the
hydraulic oil reservoir with a plug.
Remove noise insulation panel in the

middle as well as on left and right
-arrows-.
The fig. shows the noise insulation on

vehicles with 1.9 ltr./66 kW TDI and 1.9
ltr./50 kW SDI engines. The noise
insulations of the other engine versions
differ from the fig.
550
Press the track rods off the steering arm
using the extractor Matra -176-.
Note
Screw down the hexagon nut -1-

sufficiently until the track rod extractor
cannot damage the thread.
Use a pan to collect the drained off
hydraulic oil.
Unscrew the pressure line -2- (expansion

hose) from the power-steering gear and
close with a plastic bag and adhesive
tape.
Shut off the threaded bore for the

pressure line connection -2- at the power-
steering gear (e.g. with a plastic screw
plug).
The return line -1- can only be screwed off

the power-steering gear once the assembly
carrier has been lowered.
Slacken the pendulum support on the
gearbox side. To do so, release hexagonal

screws -1- and -2-.
551
Unscrew screws for mounting bracket
-arrows-.
Note
Only on gearbox 02K.
Position gearbox jack with adapter, e.g.
-V.A.G 1383A- with -V.A.G 1359/2-.
Release screws -1- for power-steering
gear.
Release screws -2- and -3- for assembly
carrier.
Lower assembly carrier.
Unscrew return line from clamp -1- and
rotary slide valve housing -2-.
Shut off the return line with a plastic bag
and adhesive tape.
Shut off the threaded bore for the return

line connection at the rotary slide valve
housing -2- (e.g. with a plastic screw
plug).
Unscrew fixing screws for power-steering
gear and remove power-steering gear

towards the rear.
Install
WARNING
After the installation of the power-steering
552
gear, the vehicle must be aligned.
Note
When tightening the lines, ensure that

t
the lines cannot touch or chafe.
Use new gasket rings for the hose/line

t
connections.
Coat the sealing sleeve on the steering

t gear with lubricant, e.g. lubricating soap,
before installing the steering gear.
After positioning the steering gear on the

drive shaft make sure that the sealing
sleeve on the steering gear is not bent on
t the assembly plate and it correctly seals
the footwell opening. Otherwise this
could cause water penetration and/or
noise.
t Make sure all sealing surfaces are clean.
t Required tightening torques Chapter.
Before fitting the power-steering gear

t check the centre position of the gear rack
Anchor.
Check the centre position of the power-

steering gear, if necessary adjust
Anchor.
553
Insert the power-steering gear with the
guide bushing -1- into the assembly

carrier and screw in the screws by hand.
Secure the return line -1- with the
retaining clip -3- and the hexagon nut -2-

to the clamp with rubber insert -4-.
Note
A distance of 10 mm must be maintained

between the return line -1- and the power-
steering gear -5--arrow-.
Secure the return line with new gasket
rings to the rotary slide valve housing.
Check the sealing sleeve at the steering
gear pinion for correct fit.
Raise the assembly carrier and while

doing so, guide the steering gear pinion
into the opening on the base of the
vehicle.
First of all tighten the assembly carrier
with old screws and to the recommended

tightening torques.
Note
554
Within the scope of the chassis alignment,
the old screws for the assembly carrier
attachment must be replaced with new
screws.
Tighten screws for power-steering gear
on the assembly carrier.
Secure the pressure line with new gasket
Screw on pendulum support and bracket
of exhaust system.
Screw on mounting bracket for shift
linkage (only on gearbox 02K).
Insert track rods into steering arm and

tighten. If the joint stub turns along when
tightening, counterhold using an Allen
key (SW 6 mm).
Mount return line to hydraulic oil
reservoir.
Remove the hose clamp from the suction
line.

pinion and tighten with new screw; 30
Nm.
Tighten the Allan screw of the clamping
ring to 17 Nm.
Top up with hydraulic oil Chapter.
Install noise insulation panel.
Align the vehicle Chapter.
Within the scope of the chassis

alignment, the old screws for the
assembly carrier attachment must be

replaced with new screws and tightened
to the specified tightening torque.
Repairing power-steering gear (ZF)
555
t Puller Kukko -V/176-
t Caliper gauge
t Clamp pliers for hose clamp, e.g. -V.A.G 1275-
Semi-fluid gear lubricant -TL733-, -NO 52733 00- e.g. -DEA ORNA F6 EPO (AOF 063 000
t
04)-
Note
Always replace the steering components -Pos. 1- up to -Pos. 9- after an accident or in the
t
event of damage to the front axle.
No provision is made for repairing on the power-steering gear. The cause of any problems
t which may arise is determined by the pressure test and tightness test. If there is a fault,
replace the power-steering gear.
t Only use original warm-type clamps.
Only use steering gear grease -AOF 063 000 04- in order to grease the gear rack (filling
t
capacity 23 ... 27 g).
556
1- Right track rod end
t press off the steering arm Chapter
t check Anchor
t removing and installing Anchor
t Check fitting position
t changed as of vehicle identification number TMBZZZ1U12W2074066 Chapter
2- Counternut, 50 Nm
t replace
t removing - open with cutting pliers
t tensioning Anchor
4- Bellows
t It is only possible to change the bellows on a removed steering gear
t before removing boot detach the track-rod end Chapter
inspect for wear (cuts, splits), inspect sealing surfaces and sealing lips for cleanliness or
t
damage
t replace
t tensioning Anchor
6- Track rod
t Tightening torque on steering rack: 75 Nm
t left and right track rod adjustable
7- Clamp with rubber insert
8- Power-steering gear
t no provision made for repairs
t adjust Chapter
t Inspecting centre position Anchor
9- Left track rod end

557
t check Anchor
Inspecting play, attachment and boots of track rod ends
On a raised vehicle (wheels clear of the ground) inspect play by moving the track rods and
the wheels, specified value play: no play
Inspect attachment.
Inspect boots for damage and correct installation.
Remove and install track rod ends
Removing
Press the track rod off the steering arm Chapter.
Slacken the hexagon nut -2- and release

the track rod end -3- from the track rod
-1-.
Install
Note
Track rod ends and track rods modified as

t of vehicle identification number
TMBZZZ1U12W2074066 Chapter.
A mixed assembly of previous and

t modified track rod ends or track rods is
not permissible Chapter.
The track rod ends must not be fitted

t
laterally reversed.
558
When fitting, pay attention to the
t
marking of the track rod end:
I - Left track rod end -L-
II - Right track rod end -R-
Pay attention to the new marking on

t
modified track rod ends Chapter.
Turn the track rod end up to the stop on

the track rod and align it in such a way
that the stud of the track rod end is in the
installation position.
Tighten counternut to 50 Nm.
Insert the track rod into the steering arm

and tighten the self-locking hexagon nut
to 45 Nm. If the joint stub turns along

when tightening, counterhold using an
Allen key (SW 6 mm).
Check the toe-in of the front axle and the
position of the steering wheel, if

necessary adjust.
Removing and installing track rods
Note
The track rods can only be removed and

installed if the steering gear is removed.
Removing
Clean outside of power steering gear in
the area of the boot.
Open the warm-type clamp and push
back the bellows.
559
Release the track rod from the gear rack.
To do so, use torque wrench with open-
jawed wrench insert SW 34, e.g. -V.A.G
1332- with -V.A.G 1332/5-. In order to
release, it is necessary to counterhold
with an open-end wrench (SW 21).
Install
Note
Track rod ends and track rods modified as

t of vehicle identification number
TMBZZZ1 Ul2W2074066 Chapter.
A mixed assembly of previous and

t modified track rod ends or track rods is
not permissible Chapter.
In any case, both track rods must be

t replaced when changing the track rods
Chapter.
Turn the track rod on the gear rack and

tighten to 75 Nm. To do so, use torque
wrench with open-jawed wrench insert
SW 34, e.g. -V.A.G 1332- with -V.A.G

1332/5-. In order to tighten, it is
necessary to counterhold with an open-
end wrench (SW 21).
Note
Align track rod in such a way that the stud

of the track rod end is in the installation
position.
steering gear Anchor.
Install bellows Anchor.
Check the centre position of the gear rack

of the power-steering gear, if necessary
adjust
Note
Before installing the power-steering gear

t
place the gear rack in centre position.
t The dimension -a- must be the same on

560
the right and left side of the power-
steering gear. If the dimension on the two
sides is not the same, distance -a- must
be corrected.
Check dimension -a-, if necessary adjust.
-a- = 30.5 mm
Install bellows
Inspect boot for wear (cuts, splits) and

inspect sealing surfaces for boot
cleanliness.
Note
Twisted bellows wear fast. Replace bellows

if damaged
Tighten the warm-type clamp using the
hose binding claw, e.g. -V.A.G 1275-.
561
Modified track rod ends
The manufacturing process for the track rod ends was optimized. The outer shape and length
of the thread stem do not change through this.
The track rods must be adapted according to the modified track rod ends Chapter.
Installed as of:
Vehicle identification number TMBZZZ1U2W2074066
Distinguishing features of the previous

track rod ends
Wrench contact area on the shank, with

1 marking R or L wrench size 22 mm
- dimension -a- = 74 -1 mm. The shank
-arrow- is round.
WARNING
These track rod ends must not be installed

on track rods which have the dimension
length -a- Chapter.
562
Distinguishing features of the modified
track rod ends
A - Right track rod end
Hexagon on thread stem, wrench size

1 - 19 mm dimension -a- = 94 + 0.5 mm
marking A for the right
B - Left track rod end
Hexagon on thread stem, wrench size

1 - 19 mm dimension -a- = 94 + 0.5 mm
marking B for the left
WARNING
These track rod ends must not be installed

on track rods which have the dimension
length -a- Chapter.
Modified track rods
The track rods were adapted because of the modified track rod ends.
The track rods were shortened in comparison with the previous version.
Installed as of:
Vehicle identification number TMBZZZ1U2W2074066
Distinguishing feature of the previous track rod

Dimension -a- = 343,1 mm
Distinguishing feature of the modified track rod
Dimension -a- = 318,9 mm
WARNING
A mixed assembly of previous and modified track

rods is not permissible. In any case, both track
rods must be replaced. In addition, the modified
track rods must not be fitted with the previous
track rod ends.
Disposing of the power-steering gear
563
t Catch pan for hydraulic oil
Note
The oils used in the power-steering gears do not contain any harmful substances. These oils may be
t
disposed of together with the drained engine and gearbox oil.
t Dispose of used oils in compliance with the applicable environmental regulations.
Used oils (this concept refers to used engine and gear oils including ATF as well as mineral hydraulic
t oils), suitable for preparation must never be mixed with brake fluid, antifreeze agent, artificial resin or
thinners, chemicals etc.
When disposing of used parts comply with the legal specifications as there are minor residual amounts of
t
hydraulic oil in the power-steering gears.
Loosen the pipes -arrows A- by removing the

clips from the power-steering gear. The clips
must not be re-used.
Hold the power-steering gear over a catch pan
and repeatedly turn the steering pinion from
stop to stop until no more hydraulic oil runs out

of the bores. Do not shut off the bores -arrows
B-.
Disposing of the power-steering gear.
Adjusting the power-steering gear (ZF)
Note
Two mechanics are required for this adjustment. The adjustment must be done when the engine is not
running.
Raise vehicle with lift platform.
l Wheels in a straight ahead position.
Move the steering wheel alternately on the centre axle (approx. 30). If the steering clearance is too
great a rattling noise will be audible.
564
The second mechanic carefully turns the
adjusting screw (arrow) so far into the cover
until no more rattling noises are heard inside

the vehicle.
When performing a test drive, note that the
steering must automatically return to the
straight ahead position after a manoeuvre or

cornering without sticking. Correct the
adjustment if necessary.
Secure the adjusting nut against turning with a

punch mark in the collar of the steering gear
housing.
Check the hydraulic oil level of the power-assisted steering, top up if necessary
t Hydraulic oil -TL52 146-, -N 052 146 00- e.g. -PENTOSIN CHF 11S(G002 000)-
Note
t Delivery inspection: oil level at MAX marking BookletOctavia
t Inspection service: oil level between MIN and MAX marking BookletOctavia
Hydraulic oil in a cold condition:
Do not start the engine and put the front wheels in a straight ahead position
Unscrew screw cap.
Wipe the oil dipstick with a clean cloth.
565
Tighten the cap by hand and unscrew again.
Only the oil level for a previously fully screwed in lid applies.
Check oil level: The oil level must be in
the area of the MIN marking (i.e. up to

2 mm above or below this marking).
Note
If the oil level is above the given range,

t
drain off some oil.
Check the hydraulic system for leaks if

the oil level is below the given range
t
Chapter. It is not enough to simply top
up the oil.
Screw in screw cap and tighten to 2 Nm.
Hydraulic oil at a normal operating

temperature (above approx. 50C):
Let the engine run at idling speed for
approx. 2 minutes with the front wheels

pointing straight ahead.
Unscrew screw cap.
Wipe the oil dipstick with a clean cloth.
Tighten the cap by hand and unscrew
again.
Only the oil level for a previously fully

screwed in lid applies.
Check oil level: The oil level must be
between the MIN and MAX markings.
Note
If the oil level is above the given range,

t
drain off some oil.
Check the hydraulic system for leaks if

the oil level is below the given range
t
Chapter. It is not enough to simply top
up the oil.
Screw in screw cap and tighten to 2 Nm.
566
Draining, filling and bleeding the power-assisted steering system
t Hydraulic oil -TL52 146-, -N 052 146 00- e.g. -PENTOSIN CHF 11S(G002 000)-
Draining
Do not let the engine run and raise the vehicle until the front wheels are fully off the
ground.
Place the catch pan for hydraulic oil underneath.
Open the hydraulic system on the suction side and return flow side and drain the
hydraulic oil.
Press out the residual hydraulic oil by turning the steering repeatedly from stop to stop.
Lower vehicle and re-connect hydraulic lines.
Note
t Dispose of hydraulic oil in compliance with the applicable environmental regulations.
Filling and bleeding
Note
t Only fill an empty hydraulic system when the engine is cold.
t Hydraulic oil -G 002 000-.
t Hydraulic oil amount in the system: 0.7 ... 0,91.
Top up hydraulic system Chapter.
If the hydraulic system is empty, fill up
the hydraulic oil reservoir until the MAX

marking on the oil dipstick is reached.
Raise the vehicle until the front wheels
are fully off the ground, put the front

wheels in a straight ahead position.
With the engine off, turn the steering
wheel 10 x from stop to stop.
Check the hydraulic oil level, top up if
necessary Chapter.
Lower the vehicle.
Start engine and run for approx. 5

seconds, the vane pump suctions
567
hydraulic oil.
Switch off engine.
necessary Chapter.
Start engine.
Turn steering wheel 10 x from stop to
stop.
Therefore, ask a 2nd mechanic to

observe the hydraulic oil level in the
reservoir and if necessary top up with
hydraulic oil so that no air can be sucked
in. If no air bubbles in the reservoir

escape out of the return line, the
hydraulic system is bled. If air bubbles
escape repeatedly, the bleeding
procedure must be repeated.
Switch off engine.
necessary Chapter.
Any residual air in the steering system will

automatically escape while driving for
approximately 10 to 20 km.
Checking the power steering system for leaks
Note
If metal swarf is found in the hydraulic oil and/or in the reservoir, the reservoir as well as
t
the suction and pressure lines must be cleaned very carefully and if necessary replaced.
Check the power steering system for tightness after assembly work and in the event of
t
hydraulic oil loss in the reservoir.
Start engine.
Turn the steering wheel in both directions up to the end stop and hold for a short while.
This will build up the highest possible pressure.
Check all line and hose connections for correct position and tightness.
In the event of leaks tighten the line or hose connections to the allowed tightening torques
or replace the seal or line.
Check hoses and lines for leaktightness. If there are leaks replace the relevant hose or
568
line.
Check vane pump for tightness. If there are leaks, replace the vane pump.
Check the hydraulic oil reservoir for tightness. If there are leaks, replace the reservoir.
Check the level of hydraulic oil, if necessary top up with oil Chapter.
Note
If there is a repeated loss of hydraulic oil from the reservoir and if the hoses and lines as well
as their connections, the vane pump and the reservoir have been thoroughly inspected
repeatedly, remove and inspect the power-assisted steering gear.
Removing the power-assisted steering gear Chapter.
Check the gasket ring for steering pinion
on the valve housing of the power-

assisted steering gear -arrow A- for leaks.
Open warm-type clamp of boot and push
back boot.
Check gear rack gasket rings -arrow B-
for leaks.
If hydraulic oil is visible in the steering gear

housing and/or in the boot, replace the
power steering gear.
Installing the power-assisted steering
drive Chapter.
Note
If there is no more hydraulic oil in the

reservoir, the vane pump may have run
dry and may have been damaged.
Replace vane pump Chapter.
569
570
Power steering noises
A closed hydraulic system will always produce running noise.
When the vehicle is stationary with engine running, hissing noises always occur if the steering
wheel is slowly turned or the steering is turned up to the end stops (this must only occur
briefly!).
The increased pumping noise in the steering end stops (during parking manoeuvers) is
system related and technically unavoidable.
For noises that differ from the usual technically unavoidable operating noises take the
following measures:
Check the hydraulic oil level in the reservoir Chapter.
Check the feed pressure of the vane pump Chapter.
Check the connections for leaks (air in the system).
Check V-belt tension.
Check routing of the suction and pressure lines (lines pinched or in contact with other
vehicle parts).
Check the steering gear mounting on the assembly carrier.
Check the screw connection of the vane pump at the bracket/engine.
Check the screw connection of the belt pulley.
Note
In order to determine if the noises come from the power-assisted steering system, it is
recommended to remove the V-ribbed belt of the vane pump and run the engine without vane
pump.
Summary of components of power-steering gear - RHD vehicles
Note
If the front axle is damaged as a result of an accident certain steering components must be
t
replaced Chapter.
No provision is made for repairing on the power-steering gear. If there are any complaints
t
about the steering gear, replace it.
t Only use semi-fluid gear lubricant AOF 063 000 04 to grease the gear rack (filling capacity
571
23 to 27 g).
t Oil quantity in the system: 0.7 ... 0.9 Itr.
1- Heat shield
572
2- Nut, 23 Nm
3- 23 Nm
4- Pressure line (expansion hose)
t from the vane pump to the power-steering gear
5- Gasket rings
6- Hollow screw, 38 Nm
t M14 x 1.5
7- Nut, 23 Nm
Fitting position:
t Arrow on the clamp points in the direction of travel
t replace the clamp if the thread of the weld nut is damaged
t adjust Chapter
11 - 20 Nm + 90
12 - 20 Nm + 90
13 - 20 Nm + 90
14 - 40 Nm + 90
15 - Pendulum support
16 - 20 Nm + 90
17 - 100 Nm + 90
573
18 - 100 Nm + 90
20 - Steering-knuckle arm of the wheel-bearing housing
21 - Counternut, 50 Nm
22 - Pressure line
t M14 x 1.5
t M16 x 1.5
25 - Gasket rings
26 - Return-flow line
t from the power-steering gear to the reservoir for central hydraulic oil
27 - Sealing sleeve
t Pay attention to installation instructions Chapter
28 - 20 Nm + 90
29 - Steering column universal joint
Removing and installing hydraulic oil reservoir
574
1- Reservoir with screw cap and oil dipstick
t Tighten screw cap to 2 Nm
t Check the level of hydraulic oil, top up if necessary Chapter
2- Return-flow line
3- Spring strap clamp
t to open and close use pliers for spring strap clamps
t The tensioning eyes must face to the top
4- Suction line
5- 10 Nm
Removing and installing the power-assisted steering gear - RHD vehicles

575
t Extractor Matra -V 176-
t Plug for hydraulic oil reservoir (commercially available)
Plastic screw plugs for line connections on the power-assisted steering gear (commercially
t
available)
Note
Apart from replacing the bellows and the track rods, no provision is made for further
t
repairs.
t Absolute cleanliness is required when working on the power steering.
t Thoroughly clean the connection points and their surroundings before releasing.
Place removed parts on a clean surface and cover if the repair cannot be carried out
t
immediately.
t Disposal Chapter.
Removing
576
Unscrew the plastic nuts -2- and the
plastic screw with clamp -1- and remove
the cover -A-.
Release screw -1-.
WARNING
Bring the steering wheel in its central

position (with the wheels straight ahead)
and make sure that it does not turn during
repairs as this could damage the coil
spring of the airbag unit.
Pinch off the suction line -1- (hydraulic oil
reservoir/vane pump) with the hose

clamp -MP 7-602- near the vane pump.
The fig. shows the line routing and how to

pinch off the line on the 1.9 ltr./66 kW TDI
engine. For the other engine versions, the
suction line routing is modified. The suction
line must, however, be pinched off near the
vane pump.
577
Open spring strap clamps -arrow- with
pliers for spring strap clamps.
Release the return-flow line from the

hydraulic oil reservoir and allow the
hydraulic oil to flow out into a suitable
vessel.
Close the return-flow opening at the
hydraulic oil reservoir with a plug.
Remove noise insulation panel in the

middle as well as on left and right
-arrows-.
The fig. shows the noise insulation on

vehicles with 1.9 ltr./66 kW TDI and 1.9
ltr./50 kW SDI engines. The noise
insulations of the other engine versions
differ from the fig.
578
Press the track rods off the steering arm
using the extractor Matra -176-.
Note
Screw down the hexagon nut -1-

sufficiently until the track rod extractor
cannot damage the thread.
Use a pan to collect the drained off
hydraulic oil.
Loosen the screws -6- of the bracket for
the exhaust pipe.
Note
Before slackening the screws -3- and -4- for

the assembly carrier, mark the fitting
position of the assembly carrier.
Slacken the pendulum support on the
gearbox side. To do so, release hexagonal

screws -1- and -2-.
579
Position gearbox jack with adapter, e.g.
-V.A.G 1383A- with -V.A.G 1359/2-.
Release screws -1- for power-steering
gear.
carrier.
Lower assembly carrier.
Unscrew the pressure line -1- (expansion

tape.
Shut off the threaded bore for the
pressure line connection -1- (e.g. with a

plastic screw plug).
The return line -2- can only be screwed off

the power-steering gear once the assembly
carrier has been lowered.
Unscrew the return line -2- (expansion

tape.
Shut off the threaded bore for the return
line connection -2- (e.g. with a plastic

screw plug).
Unscrew fixing screws for power-steering
gear and remove power-steering gear

towards the rear.
Install
580
The threaded bush -1- must fit in the hole
Further installation occurs in reverse
order.
WARNING
After the installation of the power-steering

gear, the vehicle must be aligned.
Note
When tightening the lines, ensure that

t
the lines cannot touch or chafe.
Use new gasket rings for the hose/line

t
connections.
Coat the sealing sleeve on the steering

t gear with lubricant, e.g. lubricating soap,
before installing the steering gear.
After positioning the steering gear on the

drive shaft make sure that the sealing
sleeve on the steering gear is not bent on
t the assembly plate and it correctly seals
the footwell opening. Otherwise this
could cause water penetration and/or
noise.
t Make sure all sealing surfaces are clean.
Required tightening torques see

t
Chapter and following.
Before fitting the power-steering gear

t check the centre position of the gear rack
Anchor.

steering gear, if necessary adjust
Anchor.
Tighten the return line as well as the
pressure line with new gasket rings at the

steering gear housing.
Check the sealing sleeve at the steering
gear pinion for correct fit.
Raise the assembly carrier and while

doing so, guide the steering gear pinion
into the opening on the base of the
581
vehicle.
First of all tighten the assembly carrier
with old screws and to the recommended

tightening torques.
Note
Within the scope of the chassis alignment,

the old screws for the assembly carrier
attachment must be replaced with new
screws.
Tighten screws for power-steering gear
on the assembly carrier.
Secure the pressure line with new gasket
Screw on the pendulum support.
Install the bracket for the exhaust pipe.
Mount return line to hydraulic oil
reservoir.
Remove the hose clamp from the suction
line.

pinion and tighten with new screw; 30
Nm.
Top up with hydraulic oil Chapter.
Install noise insulation panel.
Align the vehicle Chapter.
Within the scope of the chassis

alignment, the old screws for the
assembly carrier attachment must be

replaced with new screws and tightened
to the specified tightening torque.
Repairing power-steering gear (ZF) - RHD vehicles
t Puller Kukko -V/176-
582
t Open-jawed wrench insert, e.g. -V.A.G 1332/5-
t Caliper gauge
t Clamp pliers for hose clamp, e.g. -V.A.G 1275-
Semi-fluid gear lubricant -TL733-, -NO 52733 00- e.g. -DEA ORNA F6 EPO (AOF 063 000
t
04)-
Note
Always replace the steering components -Pos. 1- up to -Pos. 9- after an accident or in the
t
event of damage to the front axle.
No provision is made for repairing on the power-steering gear. The cause of any problems
t which may arise is determined by the pressure test and tightness test. If there is a fault,
replace the power-steering gear.
t Only use original warm-type clamps.
Only use steering gear grease -AOF 063 000 04- in order to grease the gear rack (filling
t
capacity 23 ... 27 g).
1- Right track rod end

583
t check Anchor
2- Counternut, 50 Nm
t replace
t tensioning Anchor
4- Bellows
t It is only possible to change the bellows on a removed power steering gear
t before removing boot detach the track-rod end Anchor
inspect for wear (cuts, splits), inspect sealing surfaces and sealing lips for cleanliness or
t
damage
t replace
t tensioning Anchor
6- Track rod
t Tightening torque on steering rack: 75 Nm
t left and right track rod adjustable
t no provision made for repairs
t adjust Chapter
t Inspecting centre position Anchor
9- Left track rod end

584
t check Anchor
585
Summary of components: Vane pump for power-assisted steering
Summary of components for the vane pump located at the top and bottom
Note
t The figure shows a version with the vane pump located at the bottom.
For a vane pump located at the top, the same tightening torques are valid for the fixing
t screws of the vane pump as well as for the hollow screw in order to connect the pressure
line to the vane pump.
1- V-ribbed belt
t before removing mark running direction
t Assignment BookletOctavia
t removing and installing Engine, Mechanics; Rep. gr.13
2- 10 Nm + 90
3- Vibration damper
t with the belt pulley for the V-ribbed belt
4- 25 Nm
5- Tensioning element
6- Generator
586
7- Support
t The fig. shows a bracket for vehicles not fitted with air conditioning
t install free of stress -Pos. 8
8- 45 Nm
t for securing the bracket -Pos. 7- at the engine block
t install Engine, Mechanics; Rep. gr.13
9- 25 Nm
11 - Sealing ring
t replace
12 - Pressure line
13 - Sealing ring
t replace
14 - Vane pump
t for power-assisted steering
t Check feed pressure Chapter
t fill up with hydraulic oil before fitting Chapter
15 - 25 Nm
16 - Belt pulley
Note
t for vane pump for vehicles fitted with a 1.4/44 kW engine:
Before removing, the front side of the belt pulley must be marked. The belt pulley must not
t
be fitted with the front side to the vane pump.
17 - Allan screw, 25 Nm
18 - 25 Nm
PAS pressure switch
587
Note
The pressure switch screwed into the vane pump is used for the idling speed stabilisation of
the engine while moving the steering wheel when the vehicle is standing still.
1- Vane pump
2- Suction line
3- Pressure line
4- Pressure switch, 15 Nm
t switches at 4.0 MPa (40 bar)
t Test signal Injection and Ignition System; Rep. gr.24
5- Sealing ring
t replace
6- Hollow screw, 38 Nm
7- Sealing ring
t replace
8- Colour marking on suction line
t all around white or yellow, must be positioned inside the bracket (- Pos.9)
588
9- Support
10 - Nut
11 - Support
Check the feed pressure of the vane pump
Vehicles with the vane pump located at the bottom or top
t Power-assisted steering testing device, e.g. -V.A.G 1402-
t Adapter, e.g. -V.A.G 1402/1 A-
t Hose from the adapter set, e.g. -V.A.G 1402/6-
Note
If there is insufficient hydraulic oil in the reservoir always check the power-assisted
t
steering system for tightness Chapter.
If there is a leak on the power-steering gear first check the lines/line connections for
t
tightness, if necessary retighten and wipe dry.
Inspecting the gasket ring on the steering pinion and on the gear rack seal Chapter. If
t
there are leaks on the gasket ring or on the gear rack seal replace the power-steering gear.
t Disposing of the power-steering gear Chapter.
Vehicles with vane pump located at the bottom
589
Pinch off the return line with the hose
clamp -MP 7-602-.
Remove the noise insulation in the
middle.
Place the catch pan under the vane
pump to collect escaping hydraulic oil.
Pinch off suction line -1- with hose clamp
-MP 7-602-.
Disconnect the plug connector from the

pressure switch on vehicles with pressure
switch.
Unscrew the pressure line -2- at the vane
pump.
Note
For reason of clarity the surrounding was

not shown in the fig.
Connect power-assisted steering testing device, e.g. -V.A.G 1402-
590
1- Vane pump
2- Sealing ring
3- Adapter, e.g. -V.A.G 1402/1 A-
4- Hose from the adapter set, e.g. -V.A.G 1402/6-
5- Adapter, e.g. -V.A.G 1402/3-
6- Power-assisted steering testing device, e.g. -V.A.G 1402-
7- Adapter, e.g. -V.A.G 1402/2-
8- Sealing ring
9- Pressure line with banjo union
10 - Hollow screw
t for vane pump without pressure switch
11 - Hollow screw
t for vane pump with pressure switch
12 - Sealing ring
t for vane pump with pressure switch

591
13 - Pressure switch
Vehicles with vane pump located at the top
If necessary, remove engine cover.
Pinch off the return line with the hose
clamp -MP 7-602-.
Pinch off the suction line with the hose
clamp -MP 7-602-.
Place the catch pan under the vane
pump to collect escaping hydraulic oil.
Unscrew the pressure line -1- at the vane
pump.
Note
For reason of clarity the surrounding was

not shown in the fig.
Connect power-assisted steering testing device, e.g. -V.A.G 1402-
592
1- Vane pump
2- Sealing ring
3- Adapter, e.g. -V.A.G 1402/1 A-
4- Hose from the adapter set, e.g. -V.A.G 1402/6-
5- Adapter, e.g. -V.A.G 1402/3-
6- Power-assisted steering testing device, e.g. -V.A.G 1402-
7- Adapter, e.g. -V.A.G 1402/2-
8- Sealing ring
9- Pressure line with banjo union
10 - Hollow screw
Test requirements:
l V-belt/V-belt tension O.K.
l Tightness of the system.
593
l Hoses/lines are not buckled up or tied up.
Inspection:
Remove the hose clamp -MP 7-602- from the suction line and return line.
Open the shut-off valve at the manometer.
Start the engine and replenish the hydraulic oil level in the reservoir if so required.
Turn steering wheel 10 x from stop to stop.
Check feed pressure.
With the engine running at idling speed, close off the shut-off valve (no longer than 5
seconds), read off the pressure at max. steering angle and compare with the specified
value according to the following table.
Nominal pressure of the vane pump Nominal value overpressure
Engine MPa bar MPa bar
Fuel engines 9,0 90 8,5 ... 9,5 85 ... 95
Diesel engines 9,0 90 8,5 ... 9,5 85 ... 95
Note
t If the specified value is exceeded or if it is not reached, replace the vane pump.
t Remove and install the vane pump located at the top Chapter.
t Remove and install the vane pump located at the bottom Chapter.
t Disposing of the vane pump Chapter.
Switch off engine.
Pinch off the suction line and the return flow line with hose clamps -MP 7-602-.
Remove power-assisted steering testing device, e.g. -V.A.G 1402-.
594
Removing and installing vane pump
Note
Repairs on the vane pump are not foreseen. The cause of any problems which may be
t arising is determined by the pressure and tightness test. If there is a fault, replace the vane
pump.
The pumps supplied by the spare part storeroom are without oil. Therefore absolutely fill up
t with hydraulic oil before fitting -G 002 000- and turn by hand, otherwise noises or damage
to the pump could occur while driving.
t Oil quantity in the system: 0.7 ... 0.9 ltr.
Mark the rotation direction before removing the V-ribbed belt. Reversing the rotation
t direction of an already used belt may destroy it. Pay attention to the correct position of the
V-ribbed belt in the belt pulley when installing it.
t Disposal Chapter.
The version and the attachment of the vane pump as well as the bracket differ from the fig.
t according to the engine versions and thoses equipped with or without air conditioning
system.
Vehicles with 1.4/44 kW Engine:
t Before removing, the fitting position of the belt pulley must be marked.
If the belt pulley of the vane pump is installed the wrong way round, it is displaced in
t relation to the other belt pulleys. The V-ribbed belt is damaged as a result of this
displacement.
Vehicles with vane pump located at the top
t Hydraulic oil -TL52 146-, -N 052 146 00- e.g. -PENTOSIN CHF 11 S (G 002 000)-
Removing
595
The fig. shows the engine cover of the 1.9 Itr./66 kW (TDI) engine. The engine covers of the
other engine versions differ from the fig.
Remove engine cover.
1- Plug
2- Clamp
3- Bolt
The fig. shows the guidance of the V-ribbed

belt on vehicles with air conditioning
system. Different routing of V-ribbed belt
on vehicles without air conditioning
system.
Note
Mark the rotation direction before removing

the V-ribbed belt. Reversing the rotation
direction of an already used belt may
destroy it. Pay attention to the correct
position of the V-ribbed belt in the belt
pulley when installing it.
Position flat ring spanner SW 16 at
hexagon of tensioning pulley.
Swing the the tensioning pulley in -the
direction of the arrow- detension the V-

ribbed belt.
Remove the V-ribbed belt.
The fig. shows the routing of the induction

pipe on the 1.9 ltr./66 kW TDI engine. The
following work steps must only be
performed on this engine version.
Open screw clamp -3-.
Unplug connector -4-.

596
Remove induction pipe -1-.
Valid for all engine versions with and

without air conditioning system.
Unscrew belt pulley, counterhold with Allan

key (SW 9 mm).
Valid for all vehicles with air conditioning

system and vane pump located at the top.
Pinch off the suction line - hydraulic oil
reservoir/vane pump - with the hose

clamp -MP 7-602-.
Open the spring strap clamp -1- with
pliers for spring strap clamps and detach

the suction line from the vane pump.
Unscrew pressure line (expansion hose)
-2-.
597
Remove the vane pump from the
bracket.
Install
Note
The vane pumps supplied by the spare

part storeroom are without oil. Absolutely
fill up with hydraulic oil before fitting -G
t
002 000- and turn by hand, otherwise
noises or damage to the pump could
occur while driving.
The contact surfaces and the threads on

t both sides of the vane pump must be free
of paint.
Fill the vane pump with hydraulic oil via
the induction pipe -arrow B-.
Turn the hub of the vane pump by hand
until hydraulic oil drains out of the

discharge nozzle -arrow A-.
598
Insert the vane pump in the bracket and
screw in screws -1- and -2-.
Screw the belt pulley to the vane pump
with Allan screws, counterhold with Allan

key (SW 9 mm).
Install V-ribbed belt Engine,
Note
Pay attention to the correct position of the

V-ribbed belt in the belt pulley when
installing it.
Install the induction pipe on the 1.9
ltr./66 kW TDI engine.
Note
Use new gasket rings to connect the

pressure line.
Install pressure line (expansion hose).
Tightening torque of the hollow screw: 38

Nm
599
Install spring strap clamp and suction
line as shown in the fig.
The longitudinal marking -A- on the
suction line must be flush with the mould

joint -C- on the vane pump.
Remove the hose clamp -MP 7-602- from
the suction line.
Top up with hydraulic oil and if necessary
bleed the power-assisted steering system

Chapter.
Check line connections for tightness
Chapter.
Install the engine cover.
Vehicles with vane pump located at the bottom
t Hydraulic oil -TL52 146-, -N 052 146 00- e.g. -PENTOSIN CHF 11 S (G 002 000)-
Removing
Note
Mark the rotation direction before removing the V-ribbed belt. Pay attention to the correct
position of the V-ribbed belt in the belt pulley when installing it.
600
Swivel the tensioning pulley with an
open-end wrench in -direction of arrow-.
Remove the V-ribbed belt.
The fig. shows the middle and left noise

insulation on vehicles with petrol engines.
Remove middle and right noise insulation
-arrows-.
Valid for all petrol engines without air

conditioning system.
Before removing, the fitting position of
the belt pulley must be marked.
Note
If the belt pulley of the vane pump is

installed the wrong way round, it is
displaced in relation to the other belt
pulleys. The V-ribbed belt is damaged as a
result of this displacement.
601
Unscrew belt pulley, counterhold with
Allan key (SW 9 mm).
Pinch off the suction line - hydraulic oil
reservoir/vane pump - with the hose

clamp -MP 7-602-.
Open the spring strap clamp -3- with
pliers for spring strap clamps and detach

the suction line from the vane pump.
Vehicles without pressure switch (fig.)
Unscrew hollow screw -2- and remove
pressure line (expansion hose).
Vehicles with pressure switch (without fig.)
Disconnect plug from pressure switch.
Unscrew pressure switch and remove
pressure line (expansion hose).
Vehicles without and with pressure switch.
Remove vane pump -5- from bracket.
Install
Note
The vane pumps supplied by the spare

part storeroom are without oil. Absolutely
fill up with hydraulic oil before fitting -G
t
002 000- and turn by hand, otherwise
noises or damage to the pump could
occur while driving.
t The contact surfaces and the threads on

both sides of the vane pump must be free
602
of paint.
Fill the vane pump with hydraulic oil via
the induction pipe -arrow B-.
Turn the hub of the vane pump by hand
until hydraulic oil drains out of the

discharge nozzle -arrow A-.
Insert the vane pump in the bracket and
screw in screws -1- and -2-.
603
with Allan screws according to the made
marking, counterhold with Allan key (SW
9 mm).
Note
If the belt pulley of the vane pump is

installed the wrong way round, it is
displaced in relation to the other belt
pulleys. The V-ribbed belt is damaged as a
result of this displacement.
with Allan screws, counterhold with Allan

key (SW 9 mm).
Install V-ribbed belt Engine,
Note
Pay attention to the correct position of

t the V-ribbed belt in the belt pulley when
installing it.
Use new gasket rings to connect the

t
pressure line.
Install pressure line (expansion hose).
Tightening torque of the hollow screw or

the pressure switch: 38 Nm
Install spring strap clamp and suction
line as shown in the fig.

joint -C- on the vane pump.
Top up with hydraulic oil and if necessary

bleed the power-assisted steering system
604
Chapter.
Check line connections for tightness
Chapter.
Install middle and right noise insulation.
Disposing
Special of the
tools andvane pumpequipment required
workshop
Note
The oils used in the vane pump do not contain any harmful substances. These oils may be
t
disposed of together with the drained engine and gearbox oil.
t Dispose of used oils in compliance with the applicable environmental regulations.
Used oils (this concept refers to used engine and gear oils including ATF as well as mineral
t hydraulic oils), suitable for preparation must never be mixed with brake fluid, antifreeze
agent, artificial resin or thinners, chemicals etc.
When disposing of used parts comply with the legal specifications as there are minor
t
residual amounts of hydraulic oil in the power-steering gears.
Remove the vane pump.
t Vehicles with the vane pump located at the top Chapter
t Vehicles with the vane pump located at the bottom Chapter
Hold the vane pump over a catch pan

and fully drain the hydraulic oil by
turning it repeatedly or by turning the
pump.
The line connections arrows -A- and -B-

must not be shut off.
Disposing of the vane pump.
605

Skoda Octavia Mk1 01 Running Gear

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Skoda Octavia Mk1 01 Running Gear

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SKODA OCTAVIA

Chassis - Specified values

Nominal values front axle

Example of a vehicle data sticker

Brake variants and their assignment

Engine litre/k 1,4/44; 1,4/55 1,6/55 1,6/74; 1,6/75 1.9/50

Engine litre/k 1,8/132 1,9/74 1,9/96

Classification N 052 766 ZO (USA standard FMVSS 571.116 DOT 4)

Load rating-indexes (Load index): 88 = 560 kg 91 = 615 kg

Repairing front wheel suspension

l - Summary of components assembly carrier, anti-roll bar, track control arm

Special tools and workshop equipment required

Insert supporting device -MP 9-200- and

support engine/gearbox in this position.

Mark installation position of bolts -1-, otherwise

Release screws -1-.

tool as shown in the fig.

While pushing out the drive shaft make sure there

Unscrew screws -3-, if present, at the track

Release the screw -1- downwards by slightly

serration of the wheel hub.

with the new screws in the former positions.

track control arm or with the suspension strut.

the outer joint rests in the wheel bearing.

Mechanics; Rep. gr.10.

wheels do not yet touch the ground.

release by 1/2 a turn.

The torque wrench is recommended e.g. for

Special tools and workshop equipment required

Press off front bearing for track control arm

Press in front bearing for track control arm

Use acid-free lubricant, e.g. -G 294 421-, when

Pressing out and in the rear bearing for the track

Removing and installing assembly carrier

Special tools and workshop equipment required

Release screws -1-.

Press out left and right drive shaft. To do so

position the tool as shown in the fig.

While pushing out the drive shaft make sure there

steering joint and support.

Release screws -1- and -2- and remove

tensioning strap to the top.

The threaded bush -1- must fit in the hole of the

Pressing out and in rubber-metal bearing

Special tools and workshop equipment required

Pressing in rubber-metal bearing

Coat rubber-metal bearing and assembly carrier

Repairing wheel bearing housing

Special tools and workshop equipment required

Removing and installing circlip

available circlip pliers.

Press the wheel bearing out of the wheel bearing

Press the wheel bearing into the wheel bearing

After pressing in the wheel bearing, the circlip

Press the wheel hub into the wheel bearing

When pressing in the wheel hub, ensure that the

Inspecting the steering joint

Pull the track control arm down with force and

Forcefully push the wheel

For these two tests no

Removing and installing the steering joint

Special tools and workshop equipment required

Position the special tools as shown in the fig.