Brake and Clutch System, Changing Brake Fluid

03 - Service Procedures


Brake and Clutch System, Changing Brake Fluid

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





• Brake filling and bleeding tool ( VAS 5234)





Observe operating instructions for (VAS 5234)!





- Unscrew brake fluid reservoir cap.

- Extract as much brake fluid as possible using suction hose from (VAS 5234) - 1 - or using a suction bottle with built-in strainer.





• After extracting, observe that no further brake fluid runs into the reservoir (the brake fluid level in the reservoir must align with the lower edge of the strainer).

CAUTION!
Do not reuse used / extracted brake fluid!

- Install and extend Brake pedal depressor (V.A.G 1869/2 ) between driver seat and brake pedal.

- Connect adapter - 1 - to brake fluid reservoir.





• If adapter - 1 - cannot be inserted due to reasons of space, use adapter ( VAS 5234/1).

- Connect filler hose of (VAS 5234 ) to adapter.

Vehicles with Manual Transmission

- Remove cover cap from bleeder screw of clutch slave cylinder.

- Connect bleeder hose - arrow - to clutch slave cylinder - 1 -, open bleeder screw and let approximately 0.1 liters flow out. Close bleeder screw.





- Operate clutch pedal several times.

Continuation for all vehicles

- Remove caps from the bleeder screws.

- Connect collector bottle bleeder hose - 1 - to a rear bleeder screw1), open bleeder screw and allow the corresponding brake fluid quantity to flow out (see table). Close bleeder screw.





Repeat work procedure on left side of vehicle at rear.

- Connect collector bottle bleeder hose - 1 - to a front bleeder screw, open bleed screw and allow the quantity to flow out (see table). Close bleeder screw.





Repeat work procedure on left side of vehicle at front.

Sequence and Brake Fluid Capacity Table





Total quantity: approximately 1 Liter

* Including brake fluid extracted from brake fluid reservoir and quantity from clutch slave cylinder.

- Fit cover caps to bleed screws of wheel brake cylinder and brake caliper.

- Move filler lever on (VAS 5234) to position - B - (see user manual).

- Take filler hose off adapter.

- Unscrew adapter from brake fluid reservoir.

- Check brake fluid level and top off if necessary.

- Screw in sealing cap in brake fluid reservoir.

- Remove brake pedal depressor.

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