Brake and Clutch System, Changing Brake Fluid

Brake and Clutch System, Changing Brake Fluid

Notes on application and safety => [ Application Information and Safety Precautions ].

Brake fluid specification => [ Brake Fluid Specifications ].

Work procedure, change brake fluid => [ Brake Fluid, Changing ].

Application Information and Safety Precautions

• From model year 2006, a new brake fluid is introduced.

• The new brake fluid can also be used for older vehicles.

• New brake fluid can be mixed with previous brake fluid.

CAUTION!
• Brake fluid must never come into contact with fluids containing mineral oils (oil, gas, cleaning solutions). Oils containing minerals damage seals and sleeves on brake systems.

• Brake fluid is poisonous. Also, do not let brake fluid come into contact with paintwork.

• Brake fluid is hygroscopic, which means that it absorbs moisture from the air. Always store brake fluid in air-tight containers.

• Wash off brake fluid spillage using plenty of water.

• Do not reuse used / extracted brake fluid!

• Observe waste disposal regulations!

Brake Fluid Specifications

Permitted specifications:

• Brake fluid corresponding to US standard FMVSS 116 DOT 4 (previous brake fluid).

• Brake fluid conforming to VW norm VW 501 14 (new brake fluid).

Brake Fluid, Changing

Special tools, testers and auxiliary items required

• Brake charger/bleeder unit (VAS 5234)





Brake pedal depressor (V.A.G 1869/2)





=> Observe operating instructions for (VAS 5234)!

- Set the correct pressure using the brake filler and bleeder unit (VAS 5234): Chassis, Brake Systems=> Chassis, Brake Systems 47 Brake System, BleedingBrake System, Bleeding

- Unscrew brake fluid reservoir cap - 1 -.





- Extract as much brake fluid as possible using intake hose Brake charger/bleeding unit (VAS 5234).





• The strainer in the brake fluid reservoir must not be removed.

CAUTION!
Extracted brake fluid must not be re-used!

- Screw adapter - 1 - onto brake fluid reservoir.





- Install brake pedal depressor (V.A.G 1869/2) between driver's seat and brake pedal and apply tension.

- Connect charger hose of brake charger/bleeder unit (VAS 5234) to adapter.

for vehicles with manual transmission

- Procedure for changing brake fluid in the clutch system: "Transmission"=> Transmission 30 Clutch System, Bleeding "Clutch System, Bleeding".

continue for all vehicles

- Connect collector bottle bleeder hose - 1 - to left front bleeder screw, open bleed screw and allow the corresponding quantity to flow out (see table). Close bleeder screw. Torque: Chassis, Brake System=> Chassis, Brake System 47 Brake Caliper, ServicingBrake Caliper, Servicing





Repeat work procedure on right side of vehicle at front.

- Unscrew both wheels at rear axle in order to reach the bleed screws.

- Pull cover caps off brake caliper bleeder screws

- Connect collector bottle bleeder hose - 1 - to left rear bleeder screw.





- Open bleeder screw and let the corresponding amount of brake fluid (see table) flow out. Close bleeder screw. Torque: Chassis, Brake System=> Chassis, Brake System 47 Brake Caliper, Rear, ServicingBrake Caliper, Rear, Servicing

• Use a suitable bleed hose. It must seat tightly on bleed screw so that no air can enter brake system.

Repeat work procedure on right side of vehicle at rear.

Table Sequence/brake fluid quantity





Total amount: approximately 1.15 Liters

- Install cover caps on brake caliper bleeder screws.

- Move filler lever on brake charger/bleeder unit (VAS 5234) to position "B" (see operating instructions).



- Take filler hose off adapter.

- Unscrew adapter from brake fluid reservoir.

- Check brake fluid level and top off if necessary.

- Screw in cap - 1 - for brake fluid reservoir.





- Remove brake pedal depressor.

- Press clutch pedal several times.

- Check pedal pressure and brake pedal free play. Free play: Max. 1/3 of pedal travel