Service

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Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
45 - Anti-lock brake system
46 - Brakes - mechanism
47 - Brakes - hydraulics

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Technical information should always be available to the foremen and mechanics, because their
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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
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safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2018 Volkswagen AG, Wolfsburg K0056569020

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Brake master cylinder and brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Front brake FS III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Front brake FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Rear brakes CI 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Rear brake CII 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.6 Rear brakes, Bosch BIR, Caddy 2011 ▶ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Allocation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Front brakes Caddy 2011 ▶ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .en. A. G. ..V.ol.ks. w. a.g.en. A. G. . . . . . . . . . . . . . . . . . . 6
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2.4 Rear brakes Caddy 2011 ▶ . . . . . . . . . . . V. o.lk.sw . . . . . . . . . . . . . . . . . . e.s.no. t .g. . . . . . . . . . . . 6
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3 Brake test . . . . . . . . . . . . . . . . . . . .o.ris.e. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ra.nt.e . . . . . . . . 8
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3.1 General information . . . . . . . . . .s a.ut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . o.r a.c . . . . . 8
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3.2 Test for vehicles with front and all-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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1.1 General notes on anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1.2 Notes for repair work on anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
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1.3 Fault display via warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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2 Vehicle diagnosis, testing and information system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1 Connecting vehicle diagnostic tester and selecting functions . . . . . . . . . . . . . . . . . . . . . . 14

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3 Overview of fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 Electrical and electronic components and fitting locations - ABS Mark 70 (ABS/TCS) . . . . 15
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3.2 Electrical and electronic components and fitting locations - ABS Mark 60 (ABS/EDL/TCS/
ESP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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4 Control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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4.1 Assembly overview - ABS Mark 70 (ABS/TCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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4.2 Removing and installing ABS control unit J104 and ABS hydraulic unit N55 . . . . . . . . . . 21
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4.3 Separating and assembling ABS control unit J104 and ABS hydraulic unit N55 . . . . . . . . 24 his
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4.4 Connecting brake lines to hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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4.5 Assembly overview - ABS Mark 60 (ABS/EDL/TCS/ESP) . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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4.6 Removing and installing ABS control unit J104 and ABS hydraulic unit N55 . . . . . . . . . . t. Cop py
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4.7 Separating and assembling ABS control unit J104 and ABS hydraulic unit N55 . . . . . . . . gh
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4.8 Connecting brake lines to hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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5 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1 Assembly overview - speed sensor on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.2 Removing and installing speed sensor on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3 Assembly overview - speed sensor on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.4 Removing and installing speed sensor on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.5 Removing and installing ESP sensor unit G419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.6 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.1 Assembly overview - front brake caliper FS III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.4 Assembly overview - front brake caliper FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
1.5 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Contents i
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

1.6 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.1 Assembly overview - rear brake CI 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.2 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.3 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.4 Assembly overview - rear brake CII 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.5 Installation instructions for brake carrier CII 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.6 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.7 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.8 Assembly overview - rear brake CII 41 (all-wheel drive) . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.9 Assembly overview - rear brakes, Bosch BIR, Caddy 2011 ▶ . . . . . . . . . . . . . . . . . . . . . . 71
2.10 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.11 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3 Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.1 Assembly overview - handbrake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.2 Removing and installing handbrake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.3 Removing and installing handbrake cable, Caddy 2011 ▶ . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.4 Adjusting handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.5 Adjusting handbrake, Caddy 2011 ▶ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.1 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.2 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1 Front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.1 Assembly overview - brake caliper FS III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
1.2 Removing and installing brake caliper FS III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
1.3 Assembly overview - brake caliper FN3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
1.4 Removing and installing brake caliper piston FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2 Rear brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.1 Assembly overview - brake caliper CI 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.2 Assembly overview - brake agen caliper CII 41AG. d.o.es. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.3 Assembly overview y V - brake caliper Bosch BIR . .t .gu.a. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.4 Dismantling oandris assembling brake caliper . . . . . . . . .n.tee. . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2.5 Pre-bleeding
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3 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
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3.1 General notes on brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

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3.2 Pre-bleeding hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

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3.3 Bleeding hydraulic system following standard procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 100

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3.4 Subsequent bleeding of hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

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3.5 Testing for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

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4 Brake servo and brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

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4.1 Assembly overview - brake servo/brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 103

4.2 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
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4.3 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

4.4 Removing and installing brake light switch F and brake pedal switch F47 to model year
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2007 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.5 Removing and installing brake light switch F from model year 2007 . . . . . . . . . . . . . . . . . . 110
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4.6 Removing and installing brake light switch F , right-hand drive . . . . . . . . . . . . . . . . . . . . . . 111
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5 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

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5.1 Vacuum pump for brake servo (vehicles with diesel engine) . . . . . . . . . . . . . . . . . . . . . . . . 114
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5.2 Checking non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

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6 Brake lines/brake hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

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6.1 Removing and installing front brake hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

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6.2 Removing and installing rear brake hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
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 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

6.3 Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

6.4 Assembly overview - flanging tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.5 Work instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

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Contents iii
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

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iv Contents
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

00 – Technical data
1 Technical data
(VRL012135; Edition 10.2018)
⇒ “1.1 Brake master cylinder and brake servo”, page 1
⇒ “1.2 Front brake FS III”, page 1
⇒ “1.3 Front brake FN 3”, page 2
⇒ “1.4 Rear brakes CI 38”, page 3
⇒ “1.5 Rear brake CII 41”, page 3
⇒ “1.6 Rear brakes, Bosch BIR, Caddy 2011 ▶”, page 4

1.1 Brake master cylinder and brake servo

Brake master cylinder Diameter in mm 22
Brake servo (left-hand ∅ in inches 11
drive vehicles)
Brake servo (RHD ve‐ ∅ in inches 7/8
hicles)

1.2 Front brake FS III

Item Product control 1ZF, 1ZM wage
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3 Brake disc Diam‐ 280
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Brake disc, mm 22
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Brake disc, mm 19
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4 Brake caliper Diam‐ 54

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1. Technical data 1
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

1.3 Front brake FN 3

Item Product control 1ZE
number (PR
No.)
1 Brake caliper FN3 (15'')
2 Brake pad, mm 14
thickness
Brake pad, wear mm 2
limit without
backplate
3 Brake disc Diam‐ 288
eter in
mm
Brake disc, mm 25
thickness
AG. Volkswagen AG d
Brake disc, mmlksw
agen 22 oes
not
wear limit byV
o gu
ara
ed
is nte
4 Brake caliperthor Diam‐ 54 eo
piston s au eter in ra
c
s
mm
ce
le
un

pt
an
d
itte

Item Product control 1LJ, 1ZA

y li
rm

number (PR ab
pe

ility
No.)
ot

wit
, is n

1 Brake caliper FN3 (16'')

h re
hole

spec

2 Brake pad, mm 14
es, in part or in w

thickness
t to the co

Brake pad, wear mm 2

limit without
rrectness of i

backplate
3 Brake disc Diam‐ 312
l purpos

eter in
mm
nform
ercia

Brake disc, mm 25
thickness
m

a
com

tio

Brake disc, mm 22
n in
r
te o

wear limit
thi
s
iva

do

4 Brake caliper Diam‐ 54

r
rp

cum

piston eter in
fo

en
g

mm
n

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

2 Rep. gr.00 - Technical data

 n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se te
o
auth Caddy 2004 ➤ , Caddy 2011 ➤e or a
c
ss Brake systems - Edition 10.2018

ce
e
nl

pt
du

an
1.4 Rear brakes CI 38

itte

y li
erm

ab
ility
ot p
Item Product control 1ZF

wit
, is n
number (PR

h re
No.)

hole

spec
es, in part or in w
1 Brake caliper CI 38 (15")

t to the co
2 Brake pad, mm 11
thickness

rrectness of i
Brake pad, wear mm 2
limit without

l purpos
backplate
3 Brake disc Diam‐ 255

nf
ercia
eter in

orm
mm
m

atio
Brake disc, mm om 10

n in
or c
thickness

thi
te

sd
a
Brake disc, mm 8
iv

o
r
rp

cu
wear limit
o

m
f

en
ng
t.
4 Brake caliper Diam‐ 38
yi Co
op
piston eter in
C py
t. rig
gh
mm
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.5 Rear brake CII 41

Item Product control 1ZE, 1LJ
number (PR
No.)
1 Brake caliper CII 41 (15")
2 Brake pad, mm 11
thickness
Brake pad, wear mm 2
limit without
backplate
3 Brake disc Diam‐ 253
eter in
mm
Brake disc, mm 10
thickness
Brake disc, mm 8
wear limit
4 Brake caliper Diam‐ 41
piston eter in
mm

1. Technical data 3
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

1.6 Rear brakes, Bosch BIR, Caddy 2011 ▶

Item Product control 1ZF, 1ZE, 1ZA
number (PR
No.)
1 Brake caliper Bosch BIR
n AG. Volkswagen AG do
2 Brake pad, mm 11 lkswage es n
o ot g
thickness byV ua
d ran
ir se tee
Brake pad, wear mm 2 utho
or
limit without ss
a ac
backplate

ce
e
nl

pt
du

an
3 Brake disc Diam‐ 272

itte

y li
eter in
erm

ab
mm

ility
ot p

wit
, is n

Brake disc, mm 10

h re
thickness
hole

spec
Brake disc, mm 8
es, in part or in w

t to the co
wear limit
4 Brake caliper Diam‐ 38
piston eter in

rrectness of i
mm
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

4 Rep. gr.00 - Technical data

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

2 Allocation
⇒ “2.1 Front brakes”, page 5
⇒ “2.2 Front brakes Caddy 2011 ▶”, page 5
⇒ “2.3 Rear brakes”, page 6
⇒ “2.4 Rear brakes Caddy 2011 ▶”, page 6

2.1 Front brakes

The type of brake system installed in the vehicle is indicated by
the corresponding production control number.
♦ For allocation, refer to ⇒ Electronic parts catalogue (ETKA) .
♦ The following tables explain the PR numbers. These are im‐
portant for the brake caliper/brake disc and brake pads.
Engine Product control Front brakes
number (PR No.)
1.4 l - 55 kW1) 1ZF, 1ZM FS III (15'')
n AG. Volkswagen AG do
1.4 l - 59 kW1) lkswage es n
o ot g
byV ua
kW TDI 1)orise
d ran
1.9 l - 55 tee
th or
u2)
2.0 l - 51 kW SDI
ss
a ac
ce
le

1.4 l - 55 kW3) 1ZE FN 3 (15”)

un

pt
an
d
itte

1.4 l - 59 kW3)
y li
erm

ab
ility
1.6 l - 75 kW
ot p

wit
is n

1.9 l - 55 kW TDI3)
h re
ole,

spec

1.9 l - 77 kW TDI
urposes, in part or in wh

2.0 l - 51 kW SDI3)
t to the co

2.0 l - 103 kW TDI 1LJ FN 3 (16'')

rrectne

1) Kombi up to gross vehicle weight rating of 2,035 kg; panel van

to gross vehicle weight rating of 2,205 kg
ss

2)
o

Kombi up to gross vehicle weight rating of 2,035 kg; panel van

cial p

f in

to gross vehicle weight rating of 2,235 kg

form
mer

3) Kombi and panel van to gross vehicle weight rating of 2,280 kg

atio
om

n
c

2.2 Front brakes Caddy 2011 ▶

or

n thi
te

sd
iva

The type of brake system installed in the vehicle is indicated by

pr

cum
r
fo

the corresponding production control number.

en
ng

t.
yi Co
op
♦ For allocation, refer to ⇒ Electronic parts catalogue (ETKA) . C py
t. rig
gh ht
yri
♦ The following tables explain the PR numbers. These are im‐
p by
co Vo
by lksw
portant for the brake caliper/brake disc and brake pads. Prote
cted AG.
agen

Engine Product control Front brakes

number (PR No.)
1.2 l PETROL - 63 kW 1ZF FS III (15'')
1)

1.6 l diesel - 55 kW 1)
2.0 l diesel - 62 kW Post
2)

1.2 l petrol - 63 kW 3) 1ZE FN 3 (15”)

1.2 l petrol - 77 kW
1.6 l petrol - 75 kW LPG

2. Allocation 5
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

1.6 l diesel - 75 kW
1.6 l diesel - 55 kW 3)
2.0 l diesel - 62 kW Post
3)

2.0 l diesel - 81 kW
1.6 l diesel - 75 kW 1ZA FN 3 (16'')
1.6 l petrol - 75 kW LPG
2.0 l diesel - 81 kW
2.0 l diesel - 103 kW
1) Kombi up to gross vehicle weight rating of 2,035 kg; panel van
to gross vehicle weight rating of 2,205 kg
2) Kombi up to gross vehicle weight rating of 2,035 kg; panel van
to gross vehicle weight rating of 2,235 kg
3) Kombi and panel van to gross vehicle weight rating of 2,280 kg

2.3 Rear brakes

The type of brake system installed in the vehicle is indicated by
the corresponding production control number.
♦ For allocation, refer to ⇒ Electronic parts catalogue (ETKA) .
♦ The following tables explain the PR numbers. These are im‐
portant for the brake caliper/brake disc and brake pads.
Engine Product control Rear brakes
number
gen AG. V(PR
olkswNo.)
agen AG
d
a oes
ksw
1.4 l - 55 kW1) by
Vol 1ZF, 1ZM CIno38
t gu(15")
d ara
ise nte
1.4 l - 59 kWt1)
ho
r e or
au ac
ss TDI 1)
1.9 l - 55 kW
ce
e
nl

pt

2.0 l - 51 kW SDI2)
du

an
itte

y li

1.4 l - 55 kW3) 1ZE CII 41 (15")

erm

ab
ility
ot p

1.4 l - 59 kW3)
wit
, is n

h re

1.6 l - 75 kW
hole

spec

1.9 l - 55 kW TDI3)
es, in part or in w

t to the co

1.9 l - 77 kW TDI (FWD

and AWD)
rrectness of i

2.0 l - 51 kW SDI3)
2.0 l - 103 kW TDI 1LJ
l purpos

1) Kombi up to gross vehicle weight rating of 2,035 kg; panel van

nf
ercia

to gross vehicle weight rating of 2,205 kg

orm
m

atio

2) Kombi up to gross vehicle weight rating of 2,035 kg; panel van

om

n in

to gross vehicle weight rating of 2,235 kg

or c

thi
te

3)
sd
a

Kombi and panel van to gross vehicle weight rating of 2,280 kg

iv

o
r
rp

cu
o

2.4 Rear brakes Caddy 2011 ▶

f

en
ng

t.
yi Co
op py
The type of brake system installed in the vehicle is indicated by t. C rig
gh ht
the corresponding production control number. pyri by
Vo
o
by c lksw
cted agen
♦ For allocation, refer to ⇒ Electronic parts catalogue (ETKA) .
Prote AG.

♦ The following tables explain the PR numbers. These are im‐

portant for the brake caliper/brake disc and brake pads.

6 Rep. gr.00 - Technical data

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

Engine Product control Rear brakes

number (PR No.)
1.2 l PETROL - 63 kW 1ZF Bosch BIR (15")
1)
AG. Volkswagen AG d
agen oes
1.6 l diesel - 55 kW 1) y Volksw not
gu
d b ara
2.0 l diesel - 62 kW Post orise nte
eo
2) uth
ra
s a c
s
1.2 l petrol - 63 kW 3) 1ZE Bosch BIR (15")

ce
le
un

pt
an
d
1.2 l petrol - 77 kW

itte

y li
erm

ab
1.6 l petrol - 75 kW LPG

ility
ot p
1.6 l diesel - 75 kW

wit
is n

h re
ole,
1.6 l diesel - 55 kW 3)

spec
urposes, in part or in wh

2.0 l diesel - 62 kW Post

t to the co
3)

2.0 l diesel - 81 kW

rrectne
1.6 l diesel - 75 kW 1ZA
1.6 l petrol - 75 kW LPG

ss
2.0 l diesel - 81 kW

o
cial p

f in
2.0 l diesel - 103 kW

form
mer

atio
m

1) Kombi up to gross vehicle weight rating of 2,035 kg; panel van

o

n
c

to gross vehicle weight rating of 2,205 kg

i
or

n thi
te

sd
a

2) Kombi up to gross vehicle weight rating of 2,035 kg; panel van

iv

o
pr

c
to gross vehicle weight rating of 2,235 kg

um
r
fo

en
ng

t.
yi
3)
Co
Kombi and panel van to gross vehicle weight rating of 2,280 kg t. Cop py
rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Allocation 7
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

3 Brake test
⇒ “3.1 General information”, page 8
⇒ “3.2 Test for vehicles with front and all-wheel drive”,
page 8

3.1 General information

n AG. Volkswagen AG do
♦ The drive is provided by the roller dynamometer. lkswage es n
o ot g
byV ua
ed ran
♦ For vehicles with a manual gearbox, ensure that the gear lever oris tee
is in neutral for the test. For vehicles with an automatic gear‐
auth or
ac
box, ensure that the selector lever is in »N«. ss

ce
le
un

pt
♦ When conducting the test, observe the specifications provided

an
d
itte
by the manufacturer of the test rig.

y li
rm

ab
pe

ility
ot

wit
, is n

Note

h re
hole

spec
The brake regulation systems do not function when ignition is off.
es, in part or in w

t to the co
3.2 Test for vehicles with front and all-wheel

rrectness of i
drive
l purpos

Note

nform
ercia

Note that vehicles with all-wheel drive must only be tested on sin‐
m

a
com

t
gle-axle roller dynamometers suitable for this purpose (e.g. brake

ion in
test stand - VAS 6360- ).
r
te o

thi
s
iva

do
r

The brake test must be carried out on a single-axle roller dyna‐

rp

cum
fo

mometer.

en
ng

t.
yi Co
op
The maximum test speed is 6 km/h. C py
t. rig
gh ht
yri by
The test rigs authorised by Volkswagen fulfil these requirements. cop Vo
by lksw
cted agen
Prote AG.

8 Rep. gr.00 - Technical data

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

45 – Anti-lock brake system

1 General information
⇒ “1.1 General notes on anti-lock brake system”, page 9
⇒ “1.2 Notes for repair work on anti-lock brake system”,
page 9
⇒ “1.3 Fault display via warning lamps”, page 11

1.1 General notes on anti-lock brake system

The ABS brake system is divided diagonally. The servo-assis‐
tance is effected pneumatically by the vacuum brake servo unit.
Vehicles with ABS are not fitted with a mechanical brake pressure
regulator. Specially matched software in the control unit regulates
the brake force distribution on the rear axle.

Note

Faults in the ABS do not influence the brake system and servo
assistance. The conventional brake system remains functional
even without ABS. A change in braking behaviour is to be reck‐
oned with. After the ABS warning lamp comes on, the rear wheels
may lock prematurely during braking.
. Volkswag
n AG en AG
wage does
olks not
ABS layout in left-hand
ed
by
V
drive vehicle. gu
ara
ris nte
o
1 - Hydraulicauunit
th and control unit eo
ra
ss c
2 - Brake servo
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

The hydraulic unit -a- and control unit -b- form one component.
rrectness of i

They can be separated only when removed.

l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri by
1.2 Notes for repair work on anti-lock brake
cop Vo
by lksw
cted agen
Prote
system
AG.

♦ Before carrying out repair work on the anti-lock brake system,

determine the cause of the fault using “Guided Fault Finding”.
“Guided fault finding” is carried out using vehicle diagnostic test‐
er .

1. General information 9
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

♦ With the ignition switched off, disconnect the battery earth

strap.
♦ Before carrying out welding work with an electric welding unit
⇒ Special information; Body No. 19; Notes on safety .
♦ When working with brake fluid, observe the relevant safety
precautions and notes ⇒ page 99 .
♦ After work for which the brake system had to be opened, bleed
the brake system with brake filling and bleeding equipment -
VAS 5234- ⇒ page 99 .
♦ During the final road test, ensure that a controlled brake test
is performed at least once (pulsations must be felt at the brake
pedal).
♦ Absolute cleanliness is required when working on the anti-lock
brake system. It is not permitted to use any products that con‐
tain mineral oil, such as oil, grease etc.
♦ Thoroughly clean all unions and adjacent areas before loos‐
ening. Do not use aggressive cleaning agents such as brake
cleaner, petrol, thinners or similar.
♦ Place removed parts on a clean surface and cover them over.
♦ After separating the control unit/hydraulic unit, use the trans‐
port protection for the contact pins.
♦ If the repair is not performed immediately, carefully cover or
seal opened components. (Use sealing plugs from repair kit
1H0 698 311 A).
♦ Only use lint-free cloths.
♦ Remove packing from replacement parts immediately prior to
installation and not before.
♦ Only use genuine packed parts.
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
AG. Volkswagen AG d
♦ During painting operations, the electronic control unit can belkswagen oes
not
exposed to a maximum temperature of 95°C for only adshort by
Vo gu
ara
period, and to a maximum of 85°C for longer periodsori(approx.
se nte
2 hours). Ensure that no brake fluid enters connectors.
au
th eo
ra
ss c
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
10
by c lksw
cted
Rep. gr.45 - Anti-lock brake system
agen
Prote AG.
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

1.3 Fault display via warning lamps

Warning lamps
Item Description
1 Traction control system warning lamp - K86-
ESP and TCS warning lamp - K155-
2 Brake pad warning lamp - K32-
3 ABS warning lamp - K47-
4 Brake system warning lamp - K118-
Brake pad warning lamp - K32-
♦ If the brake pad warning lamp - K32- -2- does not go out 3 sec‐
onds after the ignition is switched on, or it comes on during
vehicle operation, the fault may be:
-a- The brake pads are worn.
Check brake pads/linings on front and rear axles. Renew worn
brake pads/linings.
-b- There is a wiring fault. ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations agen
AG. Volkswagen AG d
o
ksw es n
Vol ot g
ABS warning lamp - K47- ed by ua
ran
ris tee
♦ If ABS warning lamp - K47- -3- does not authogo out after switching or
ac
ignition on and completion of test sequence
ss then the fault may
be:

ce
le
un

pt
an
d
itte

-a- The voltage supply is below 10 volts.

y li
erm

ab
-b- There is a fault in the ABS.

ility
ot p

wit
is n

h re
ole,

WARNING

spec
urposes, in part or in wh

t to the co
In the event of an ABS fault -b-, the anti-lock brake system
remains switched off, but the brake system remains fully op‐
erational.

rrectne
-c- A temporary speed sensor fault occurred since the vehicle was
ss
last started.
o
cial p

f inform

In this case, ABS warning lamp will go out automatically after the
mer

engine is restarted and the vehicle exceeds a speed of 20 km/h.

atio
om

n
c

-d- The connection from dash panel insert to ABS control unit -
i
or

n thi

J104- is interrupted. ⇒ Current flow diagrams, Electrical fault

te

sd
a

finding and Fitting locations

iv

o
pr

cum
r
fo

-e- The dash panel insert is defective.

en
ng

t.
yi Co
op
ABS warning lamp - K47- and brake system warning lamp - K118-
C py
t. rig
gh ht
yri by
♦ If the ABS warning lamp - K47- -3- goes out but the brake cop Vo
by lksw
cted
system warning lamp - K118- -4- remains on, then the fault
agen
Prote AG.
may be:
-a- = handbrake is applied.
-b- = brake fluid level is too low (the warning lamp flashes).
Three warning tones are audible after ignition is switched on.
-c- There is a fault in the wiring leading to brake system warning
lamp -K118- . ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations

1. General information 11
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

♦ If the ABS warning lamp - K47- -3- and the brake system
warning lamp - K118- -4- light up, then the anti-lock brake sys‐
tem is defective. A change in braking behaviour is to be
reckoned with.

WARNING

After the ABS warning lamp - K47- and the brake system warn‐
ing lamp - K118- have lit up, it is possible that the rear wheels
will lock up earlier.

Traction control system warning lamp

gen AG
-. VK86-
olkswagen AG
d wa oes
olks no
♦ If the traction controldsystem
by
V warning lamp - K86- -1- does
t gu not
ar
go out after switching
orise ignition on and completion of test se‐ante
eo
quence then the au fault may be:
th
ra
ss c
There is a fault present which only affects the TCS. ABS and EBD

ce
le
un

pt
safety systems of vehicle remain fully functional ⇒ Read event

an
d
itte

memory.

y li
erm

ab
ility
-a- = short-circuit to positive in TCS button - E256- .
ot p

wit
is n

-b- = fault in activation of traction control system warning lamp -

h re
ole,

K86- . ⇒ Current flow diagrams, Electrical fault finding and Fitting

spec
urposes, in part or in wh

locations

t to the co
-c- = TSC system has been shut off by the TCS button - E256- .

rrectne
Note
ss

If traction control system warning lamp - K86- flashes while the

o
cial p

vehicle is in motion, the TCS is in operation.

inform
mer

atio

♦ If the TCS warning lamp - K86- -1- does not light up during the
om

self-test, the fault may be:

c

i
or

n thi
te

-a- = TCS warning lamp - K86- defective ⇒ carry out electrical

sd
iva

o
r

check.
p

cum
r
fo

en
ng

ESP and TCS warning lamp - K155-

t.
yi Co
Cop py
t.
♦ If the ESP and TCS warning lamp - K155- -1- does not go out
rig
gh ht
yri by
after the ignition has been switched on and the test sequence op Vo
by c lksw
has been completed, then the fault may be: cted agen
Prote AG.

A fault in the system affecting only the TCS/ESP. The ABS/EDL

and EBD safety systems on the vehicle remain fully functional ⇒
Read event memory.
-a- = short-circuit to positive in TCS and ESP button - E256- .
-b- = fault in activation of ESP and TCS warning lamp - K155-
⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐
tions.
-c- = TCS/ESP has been deactivated by TCS and ESP button -
E256- .

Note

If the ESP and TCS warning lamp - K155- flashes while the ve‐
hicle is in motion, the traction control system or ESP system is in
regulating mode.

♦ If the ESP and TCS warning lamp - K155- -1- does not light
up during the self-test, the fault may be:

12 Rep. gr.45 - Anti-lock brake system

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

-a- = ESP and TCS warning lamp - K155- defective ⇒ carry out
electrical check.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. General information 13
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

2 Vehicle diagnosis, testing and infor‐

mation system
⇒ “2.1 Connecting vehicle diagnostic tester and selecting func‐
tions”, page 14 AG. Volkswagen AG d
agen oes
ksw
2.1 Connecting vehicle diagnostic tester ol not
y V gu
d b ara
ise
and selecting functions r nte
tho eo
au ra
ss c
Special tools and workshop equipment required

ce
le
un

pt
an
♦ Vehicle diagnostic tester

d
itte

y li
erm

ab
♦ Diagnosis cable

ility
ot p

wit
is n

h re
WARNING ole,

spec
urposes, in part or in wh

♦ During a road test, you must always secure testing and

t to the co
measuring equipment on the back seat.
♦ These devices may be operated only by a passenger while

rrectne
the vehicle is in motion.

ss o
– Connect connector of diagnostic cable .
cial p

f inform
– Switch on vehicle diagnostic tester .
mer

atio
m

The vehicle diagnostic tester is ready for operation when the se‐
o

n
c

i
lector buttons for the operating modes are displayed on the
or

n thi
e

screen.
t

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iva

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– Switch on ignition.

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– Select one after another:
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♦ Brand
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♦ Model
agen
Prote AG.

♦ Model year
♦ Body version
♦ Engine code
– Confirm input data.
– Wait until vehicle diagnostic tester has read all control units in
vehicle.
– Select desired function on vehicle diagnostic tester ⇒ Vehicle
diagnostic tester.

14 Rep. gr.45 - Anti-lock brake system

 n AG. Volkswagen AG doCaddy 2004 ➤ , Caddy 2011 ➤
wage es n
yV
olks Brake ot gsystems - Edition 10.2018
d b ua
ran
ir se tee
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3 Overview of fitting locations au ac
ss

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pt
⇒ “3.1 Electrical and electronic components and fitting locations

an
d
itte
- ABS Mark 70 (ABS/TCS)”, page 15

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erm

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ility
⇒ “3.2 Electrical and electronic components and fitting locations

ot p

wit
- ABS Mark 60 (ABS/EDL/TCS/ESP)”, page 17
is n

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ole,
3.1 Electrical and electronic components and fitting locations - ABS Mark 70

spec
urposes, in part or in wh

(ABS/TCS)

t to the co
1 - ABS control unit - J104-

rrectne
❑ Location: on the hy‐
draulic unit on right in

ss o
engine compartment.
cial p

f in
❑ Can be checked in “Gui‐

form
mer

ded Fault Finding” using

atio
m

vehicle diagnostic tester

o

n
c

i
or

n
❑ Do not separate con‐

thi
e

nector before success‐

t

sd
iva

o
fully completing self-di‐
pr

cum
r
fo

agnosis. Switch ignition

en
ng

t.
off before separating
yi Co
op
connector.
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yri
❑ Removing and installing
p by
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by lksw
⇒ page 21 Prote
cted AG.
agen

2 - ABS hydraulic unit - N55-

❑ Location: on right in en‐
gine compartment.
The hydraulic unit consists of
the components:
❑ ABS hydraulic pump -
V64-
❑ Can be checked in “Gui‐
ded Fault Finding” using
vehicle diagnostic tester
❑ Valve block (contains in‐
let and outlet valves).
❑ ABS hydraulic pump -
V64- and valve block
must not be separated
from one another.
❑ Removing and installing
⇒ page 21
3 - Brake pad warning lamp -
K32-
❑ Location: in dash panel insert.
❑ Function: ⇒ page 11 .
4 - ABS warning lamp - K47-
❑ Location: in dash panel insert.
❑ Function: ⇒ page 11 .
5 - Traction control system warning lamp - K86-
❑ Location: in dash panel insert.
❑ Function: ⇒ page 11 .
6 - Brake system warning lamp - K118-
❑ Location: in dash panel insert.

3. Overview of fitting locations 15

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018
❑ Function: ⇒ page 11 .
7 - Brake light switch - F- and brake pedal switch - F47-
❑ To ensure secure installation, install brake light switch only once.
❑ Adjusting ⇒ page 109 AG. Volkswagen AG d
agen oes
❑ Can be checked in “Guided Fault Finding”yusing olksw vehicle diagnostic tester not
V gu b ara
ed nte
8 - TCS button - E256- thoris e or
au
❑ Located in centre console ss
ac

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le
un
9 - Diagnosis connection

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❑ Location: Driver footwell cover.
erm

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ility
ot p

10 - Front right speed sensor - G45- / front left speed sensor - G47-

wit
is n

❑ Can be checked in “Guided Fault Finding” using vehicle diagnostic tester

h re
ole,

❑ Removing and installing ⇒ page 37

spec
urposes, in part or in wh

t to the co
11 - Wheel bearing housing
12 - Wheel bearing/wheel bearing unit

rrectne
❑ ABS sensor ring is installed in wheel bearing
13 - Rear right speed sensor - G44- / rear left speed sensor - G46-

ss
❑ Can be checked in “Guided Fault Finding” using vehicle diagnostic tester

o
cial p

f in
❑ Removing and installing ⇒ page 38

form
mer

14 - Axle assembly with stub axle

atio
om

n
c

15 - Wheel hub with wheel bearing

i
or

n thi
te

sd
❑ ABS sensor ring is installed in wheel bearing
iva

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t.
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Cop py
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pyri by
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cted agen
Prote AG.

16 Rep. gr.45 - Anti-lock brake system

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

3.2 Electrical and electronic components and fitting locations - ABS Mark 60
(ABS/EDL/TCS/ESP)

1 - ABS control unit - J104-

❑ Location: on the hy‐
draulic unit on right in
engine compartment.
❑ Can be checked in “Gui‐
ded Fault Finding” using
vehicle diagnostic tester
❑ Do not separate con‐
nector before success‐
fully completing self-di‐
agnosis. Switch ignition
off before separating
connector.
❑ Removing and installing
⇒ page 29
Volkswagen AG
2 - ABS hydraulic unit - N55- wage
n AG. does
olks not
❑ Location: on right in en‐ ed by V gu
ara
gine compartment. ho
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The hydraulic unit consistsssof c
the components:

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❑ ABS hydraulic pump -

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rm

ab
V64-
pe

ility
❑ Brake pressure send‐
ot

wit
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er 1 - G201-

h re
hole

❑ Can be checked in “Gui‐

spec
es, in part or in w

ded Fault Finding” using

t to the co
vehicle diagnostic tester
❑ Valve block (contains in‐
let and outlet valves).
rrectness of i

❑ ABS hydraulic pump -

l purpos

V64- and valve block

must not be separated
from one another.
nform
ercia

❑ Removing and installing

m

⇒ page 29
com

tion in
r

3 - Brake pad warning lamp - K32-

te o

thi
s
iva

❑ Location: in dash panel insert.

do
r
rp

cum

❑ Function: ⇒ page 11 .
fo

en
ng

t.
yi Co
4 - ABS warning lamp - K47- t. Cop py
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❑ Location: in dash panel insert.
ht
pyri by
Vo
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❑ Function: ⇒ page 11 .
by
cted agen
Prote AG.
5 - ESP and TCS warning lamp - K155-
❑ Location: in dash panel insert.
❑ Function: ⇒ page 11 .
6 - Brake system warning lamp - K118-
❑ Location: in dash panel insert.
❑ Function: ⇒ page 11 .
7 - Brake light switch - F- and brake pedal switch - F47-
❑ To ensure secure installation, install brake light switch only once.
❑ Adjusting ⇒ page 109

3. Overview of fitting locations 17

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018
❑ Can be checked in “Guided Fault Finding” using vehicle diagnostic tester
8 - TCS and ESP button - E256-
❑ Located in centre console
9 - ESP sensor unit - G419-
❑ Location: Behind glove compartment
❑ Fitting location: not installed in vehicles with ABS up to model year 2007
❑ Fitting location: as of 2008 installed in ABS control unit - J104-
❑ Combined lateral acceleration sender - G200- and yaw rate sender - G202-
❑ Combined in one housing.
❑ Can be checked in “Guided Fault Finding” using vehicle diagnostic tester
❑ Removing and installing ⇒ page 39
10 - Steering angle sender - G85-
❑ Location: on steering column between steering wheel and steering column switch.
❑ Can be checked in “Guided Fault Finding” using vehicle diagnostic tester
❑ Removing and installing ⇒ page 40
11 - Diagnosis connection
❑ Location: Driver footwell cover.
12 - Front right speed sensor - G45- / front left speed sensor - G47-
❑ Can be checked in “Guided Fault Finding” using vehicle diagnostic tester
❑ Removing and installing ⇒ page 37 AG. Volkswagen n AG do
wage es n
13 - Wheel bearing housing Volks ot g
by ua
ed ran
14 - Wheel bearing/wheel bearing unit horis tee
ut or
❑ ABS sensor ring is installed in wheel sbearing
sa ac

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e
nl

15 - Rear right speed sensor - G44- / rear left speed sensor - G46-

pt
du

an
itte

y li
❑ Can be checked in “Guided Fault Finding” using vehicle diagnostic tester
erm

ab
❑ Removing and installing ⇒ page 38

ility
ot p

wit
, is n

16 - Axle assembly with stub axle

h re
hole

spec
17 - Wheel hub with wheel bearing
es, in part or in w

❑ ABS sensor ring is installed in wheel bearing t to the co

rrectness of i
l purpos

nf
ercia

orm
m

atio
om

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te

sd
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t.
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Cop py
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gh ht
pyri by
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cted agen
Prote AG.

18 Rep. gr.45 - Anti-lock brake system

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

4 Control unit and hydraulic unit

⇒ “4.1 Assembly overview - ABS Mark 70 (ABS/TCS)”,
page 19
olkswagen AG
en AG. V
⇒ “4.2 Removing and installing ABS control unit
olks J104 and ABS
wag does
not
hydraulic unit N55 ”, page 21 ed
byV gu
ara
ris nte
⇒ “4.3 Separating and assembling ABS
aut
h control unit J104 and ABS
o eo
ra
hydraulic unit N55 ”, page 24 ss c

ce
e
nl
⇒ “4.4 Connecting brake lines to hydraulic unit”, page 26

pt
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an
itte

y li
⇒ “4.5 Assembly overview - ABS Mark 60 (ABS/EDL/TCS/ESP)”,
erm

ab
page 26

ility
ot p

wit
, is n

⇒ “4.6 Removing and installing ABS control unit J104 and ABS

h re
hole

hydraulic unit N55 ”, page 29

spec
es, in part or in w

⇒ “4.7 Separating and assembling ABS control unit J104 and ABS

t to the co
hydraulic unit N55 ”, page 34
⇒ “4.8 Connecting brake lines to hydraulic unit”, page 35

rrectness of i
4.1 Assembly overview - ABS Mark 70 (ABS/TCS)
l purpos

1 - ABS control unit - J104-

nf
ercia

orm
❑ Removing and installing
m

atio
m

⇒ page 21
o

n in
or c

2 - ABS hydraulic unit - N55-

thi
te

sd
iva

❑ Removing and installing

o
r
rp

cu
⇒ page 21
o

m
f

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ng

t.
yi Co
3 - Brake line . Cop py
rig
ht
❑ Brake master cylinder/ rig ht
py by
primary piston circuit to
co Vo
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cted
hydraulic unit
agen
Prote AG.

❑ Identification: union nut

with thread M10x1
4 - Brake line
❑ Brake master cylinder/
secondary piston circuit
to hydraulic unit
❑ Identification: union nut
with thread M12x1
5 - Brake line
❑ To front left brake cali‐
per
❑ Identification: union nut
with thread M12x1
6 - Brake line
❑ To front right brake cali‐
per
❑ Identification: union nut
with thread M10x1
7 - Brake line
❑ To rear left brake caliper
❑ Identification: union nut
with thread M12x1

4. Control unit and hydraulic unit 19

 Caddy 2004 ➤ , Caddy 2011 ➤
AG. Volkswagen AG d
Brake systems - Edition 10.2018
lksw
agen oes
n o ot g
yV ua
edb ran
8 - Brake line ris tee
tho or
❑ To rear right brake caliper au ac
ss
❑ Identification: union nut with thread M10x1

ce
le
un

pt
an
d
9 - Torx socket head bolt, 5.5 Nm itte

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erm

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ility
10 - Holder
ot p

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11 - Hexagon bolt, 8 Nm

h re
ole,

spec
12 - Seal
urposes, in part or in wh

t to the co
❑ For brake servo.
13 - Brake servo

rrectne
❑ On petrol engines, the required vacuum is obtained at the intake connecting piece.
❑ Diesel engines are fitted with a vacuum pump to generate the necessary vacuum pressure

s
⇒ page 114 .

s o
cial p

f
❑ Operation check:

inform
mer

– With engine switched off, depress brake pedal firmly several times (to exhaust any negative pressure in

atio
the unit).
om

n
c

i
or

n thi
– Now depress brake pedal with average foot pressure, hold and start engine. If the servo unit is working
te

sd
a

properly, the brake pedal will now give perceptibly under foot (servo assistance becomes activated).
iv

o
pr

cum
r
fo

❑ If faulty, renew complete.

en
ng

t.
yi Co
❑ Removing and installing ⇒ page 107 Cop py
t. rig
gh ht
yri
14 - Sealing ring p by
o Vo
by c lksw
cted agen
15 - Tandem brake master cylinder Prote AG.

❑ Cannot be repaired. If faulty, renew complete.

❑ Removing and installing ⇒ page 105
16 - Hexagon nut, 25 Nm
❑ Renew each time after removing
17 - Sealing plug
❑ Moisten with brake fluid and press into brake fluid reservoir.
18 - Brake fluid reservoir
19 - Sealing cover
20 - Sealing plug
❑ Connection for vacuum hose.
21 - Vacuum hose
❑ Fit in brake servo.

20 Rep. gr.45 - Anti-lock brake system

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

4.2 Removing and installing ABS control unit - J104- and ABS hydraulic unit -
N55-

Special tools and workshop

equipment required

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
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aut ra
ss c

ce
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nl

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itte

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erm

ab
ility
ot p

wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
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nf
ercia

orm
m

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thi
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t.
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Cop py
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yri
♦ Torque wrench - V.A.G 1331-
p by
o Vo
by c lksw
cted agen
♦ Torque wrench - V.A.G 1410-
Prote AG.

♦ Brake pedal actuator - V.A.G 1869/2-

4. Control unit and hydraulic unit 21

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

Sealing plugs from repair kit, part number 1H0 698 311 A
The transport protection for the contact pins must always be
placed on the hydraulic unit after the control unit has been dis‐
connected from the hydraulic unit.
No warranty can be assumed for hydraulic units without transport
protection.
1 - Transport protection for valve contact pin (foam)
2 - Sealing plug M10
3 - Sealing plug M12
Removing
Fitting location:
The control unit is bolted to the hydraulic unit and is located on
right in the engine compartment.

WARNING

Do not bend the brake lines in the area of the hydraulic unit!

– Read out and note the existing control unit code.

. Volkswage n AG n AG d
wage oe
– Note or request radio Vocode
lks on vehicles with coded
s noradio if
t gu
necessary. d by ara
ise n r tee
ho
– Disconnects aubattery.
t
⇒ Electrical system; Rep. gr. 27 ; Dis‐or ac
connecting
s and reconnecting battery .
ce
e
nl

pt
du

1.9 l diesel engines:

an
itte

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erm

ab

– Unclip fuel hoses and coolant hoses from charge air pipe.
ility
ot p

wit
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– Remove bolt -1-.

h re
hole

spec

– Remove charge air pipe together with connecting hoses be‐

es, in part or in w

tween charge air cooler and intake manifold flap motor -

t to the co

V157- . To do this, slightly raise retaining clips -arrows-.

– Remove intake manifold flap motor - V157- ⇒ Rep. gr. 23 .
rrectness of i

Engine code BJB:

l purpos

– Remove connecting pipe together with connecting hoses be‐

tween charge air cooler and turbocharger ⇒ Rep. gr. 21 .
nf
ercia

or

– Remove air intake connecting piece ⇒ Rep. gr. 23 .

m
m

atio
m

Continued for all vehicles:

o

n in
or c

thi
e

– If cover for brake lines is installed, remove it.

t

sd
iva

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rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

22 Rep. gr.45 - Anti-lock brake system

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Release connector on control unit in direction of arrow -1- and

pull off -2-.
– Apply brake pedal depressor - V.A.G 1869/2- .
– Connect bleeder bottle hose to front left brake caliper bleeder
valve and rear left brake caliper bleeder valve and open bleed‐
er valves.
– Depress brake pedal at least 60 mm using brake pedal de‐
pressor - V.A.G 1869/2- .
– Close front left and rear left bleeder valve.
– Do not remove brake pedal depressor - V.A.G 1869/2- .
– Place sufficient lint-free cloths under the control unit and hy‐
draulic unit.

Note

Ensure no brake fluid gets onto contacts.

– First identify the two brake master cylinder brake lines

-A and B- and unscrew from the hydraulic unit.
– Immediately seal brake lines and threaded holes with sealing
plugs from repair set (part no. 1H0 698 311 A).
– Identify brake lines (brake calipers) -1 to 4-, unscrew and seal.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
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nl

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itte

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erm

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ility
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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
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cum
for

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ng

t.
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Cop py
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pyri by
Vo
co lksw
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cted agen
Prote AG.

4. Control unit and hydraulic unit 23

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Pull hydraulic unit with control unit upwards out of dampers.

Installing

Note

♦ Remove sealing plugs from new hydraulic unit only when the
corresponding brake line is to be fitted.
♦ If sealing plugs are removed too early from the hydraulic unit,
brake fluid can escape, and it can then no longer be guaran‐
teed that the unit can be sufficiently filled and bled.
♦ When installing, ensure that rubber dampers are not pressed
out of bracket.

– Installation is carried out in reverse order.

Observe following points when installing:
Engine codes BLS, BMM, BSU:
– Install intake manifold flap motor - V157- ⇒ Rep. gr. 23 .
– Install charge air pipe together with connecting hoses ⇒ Rep.
gr. 21 .
Engine code BJB:
– Install air intake connecting piece ⇒ Rep. gr. 23 .
AG. Volkswagen AG d
agen
– Install connecting pipe together with connecting
Vol
ksw hoses be‐ oes
not
gu
tween charge air cooler and turbocharger
ed by ⇒ Rep. gr. 21 . ara
nte
ris
ho eo
Continued for all vehicles: aut ra
ss c
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
ce
le
un

pt

necting and reconnecting battery .

an
d
itte

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erm

– Remove brake pedal actuator - V.A.G 1869/2- .

ab
ility
ot p

– Bleed brake system ⇒ page 99 .

wit
is n

h re
ole,

– Code ABS control unit - J104- . ⇒ Vehicle diagnostic tester

spec
urposes, in part or in wh

Tightening torques:
t to the co

Control unit to hydraulic unit 5.5 Nm

Hexagon bolt of hydraulic unit to bracket 8 Nm
rrectne

Brake lines to ABS unit:

Thread M10 x 1 14 Nm
ss o
cial p

Thread M12 x 1 14 Nm
f inform
mer

atio

4.3 Separating and assembling ABS control

om

n
c

unit - J104- and ABS hydraulic unit -

i
or

n thi
te

sd
a

N55-
iv

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pr

cum
r
fo

Disconnecting
en
ng

t.
yi Co
op py
– Place hydraulic unit with control unit upwards on a clean flat t. C rig
gh ht
level surface. yri
p by
o Vo
by c lksw
cted agen
Prote AG.

24 Rep. gr.45 - Anti-lock brake system

 AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara Caddy 2004 ➤ , Caddy 2011 ➤
ise nte
r
ut
ho eo
ra Brake systems - Edition 10.2018
s a c
s
– Unscrew Torx bolt -arrows-.

ce
e
nl

pt
du

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itte

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erm

ab
ility
ot p

wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Without canting it, pull control unit off from hydraulic unit

nf
ercia

-arrow-.

orm
m

atio
– Carefully pull all seals from hydraulic unit contact pins.
om

n in
or c

thi
te

WARNING

sd
iva

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f

♦ Printed circuit board becomes visible when control unit is

en
ng

t.
yi
removed.
Co
Cop py
t. rig
gh
♦ No moisture or particles of dirt may enter control unit.
ht
pyri by
Vo
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by c lksw
♦ Hydraulic pump must not be separated from hydraulic unit.
cted agen
Prote AG.

– Cover control unit solenoids with a lint-free cloth.

After separating control unit and hydraulic unit, use transport pro‐
tection for contact pins.
Assembling

WARNING

Severe shocks (e.g. dropping, impact) may destroy the control

unit. Control unit must not then be used.

• Clean surfaces before assembling.

– Push all seals -A- over contact pins slightly.

– Without canting it, place control unit onto hydraulic unit.
The seals are thus moved to end position.
– Bolt hydraulic unit and control unit with enclosed, new Torx
bolts.

Note

♦ A new control unit may be mounted on an existing hydraulic

unit max. twice to guarantee impermeability of the elastic seal.
♦ A control unit which has already been operated in a vehicle
must not be installed a second time.

4. Control unit and hydraulic unit 25

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

4.4 Connecting brake lines to hydraulic unit

On tandem brake master cylinder:
A - Primary piston circuit of brake master cylinder to hydraulic unit.
- Identification: union nut with thread M10x1
B - Secondary piston circuit of brake master cylinder to hydraulic
unit.
- Identification: union nut with thread M12x1
1 - From hydraulic unit to front left brake caliper
3 - Hydraulic unit to rear right brake caliper
4 - From hydraulic unit to rear left brake caliper

On hydraulic unit:
A - From hydraulic unit to primary piston circuit of brake master
cylinder. . Volkswage
AG n AG d
agen oes
- Identification: union nut with thread M10x1 olksw not
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B - From hydraulic unit to secondary pistonhocircuit
ris of brake master nte
eo
cylinder. aut ra
c
ss
- Identification: union nut with thread M12x1

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e
nl

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itte

1 - From hydraulic unit to front left brake caliper

y li
erm

ab
ility
- Identification: union nut with thread M12x1
ot p

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2 - From hydraulic unit to front right brake caliper.

h re
hole

spec
- Identification: union nut with thread M10x1
es, in part or in w

t to the co
3 - Hydraulic unit to rear right brake caliper
- Identification: union nut with thread M10x1

rrectness of i
4 - From hydraulic unit to rear left brake caliper
l purpos

- Identification: union nut with thread M12x1 nf

ercia

4.5 Assembly overview - ABS Mark 60 (ABS/EDL/TCS/ESP)

orm
m

atio
om

n in
or c

thi
te

sd
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rp

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o

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f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

26 Rep. gr.45 - Anti-lock brake system

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

1 - ABS control unit - J104-

❑ Removing and installing
⇒ page 29
2 - ABS hydraulic unit - N55-
❑ Removing and installing
⇒ page 29
3 - Brake line
❑ Brake master cylinder/
primary piston circuit to
hydraulic unit
❑ Identification: ∅ 6.5 mm
and flare nut with long
thread M12x1.
4 - Brake line
❑ Brake master cylinder/
secondary piston circuit
to hydraulic unit
❑ Identification: ∅ 6.5 mm
and flare nut with long
thread M12x1.
5 - Brake line
❑ To front left brake cali‐ AG. Volkswagen AG d
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❑ Identification: ∅ d by ara
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6 - Brake line
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❑ To front right brake cali‐

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❑ Identification: ∅

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with thread M10x1.

t to the co
7 - Brake line
❑ To rear left brake caliper

rrectne
❑ Identification: ∅ 5.25 mm and flare nut with short thread M12x1.
8 - Brake line
❑ To rear right brake caliper ss o
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❑ Identification: ∅ 5.25 mm and flare nut with thread M10x1.

mer

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9 - Torx socket head bolt, 5.5 Nm

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10 - Holder
thi
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❑ Mounting bracket mounting is bolted to retainer for ABS unit on Caddy 2011 ▶
i

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11 - Hexagon bolt, 8 Nm
en
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12 - Seal
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❑ For brake servo.
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13 - Brake servo
Prote AG.

❑ On petrol engines, the required vacuum is obtained at the intake connecting piece.
❑ Diesel engines are fitted with a vacuum pump to generate the necessary vacuum pressure
⇒ page 114 .
❑ Operation check:
– With engine switched off, depress brake pedal firmly several times (to exhaust any negative pressure in
the unit).

4. Control unit and hydraulic unit 27

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Now depress brake pedal with average foot pressure, hold and start engine. If the servo unit is working
properly, the brake pedal will now give perceptibly under foot (servo assistance becomes activated).
❑ If faulty, renew complete.
❑ Removing and installing ⇒ page 107
14 - Sealing ring
15 - Tandem brake master cylinder
❑ Cannot be repaired. If faulty, renew complete.
❑ Removing and installing ⇒ page 105
16 - Heat shield
For allocation, refer to ⇒ Electronic parts catalogue (ETKA) .

17 - Hexagon nut, 25 Nm
❑ Renew each time after removing
18 - Sealing plug
❑ Moisten with brake fluid and press intoenbrake
AG. Vofluid
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19 - Brake fluid reservoir y Vol gu
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20 - Sealing cover tho eo
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21 - Sealing plug s

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❑ Connection for vacuum hose.
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22 - Vacuum hose
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❑ Fit in brake servo.

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Prote AG.

28 Rep. gr.45 - Anti-lock brake system

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

4.6 Removing and installing ABS control unit - J104- and ABS hydraulic unit -
N55-
AG. Volkswagen AG d
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♦ Torque wrench - V.A.G 1331-

♦ Ring insert tool, open, AF 11 mm - V.A.G 1410/6-
♦ Universal joint - V.A.G 1410/7-
♦ Torque wrench - VAS 6854-
♦ Brake pedal actuator - V.A.G 1869/2-
♦ Assembly tool - V.A.G 1410/8-

4. Control unit and hydraulic unit 29

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

Plugs - 1H0 698 311 A-

The transport protection for the contact pins must always be
placed on the hydraulic unit after the control unit has been dis‐
connected from the hydraulic unit.
No warranty can be assumed for hydraulic units without transport
protection.
1 - Transport protection for valve contact pin (foam)
2 - Sealing plug M10
3 - Sealing plug M12
Removing
Fitting location:
The ABS control unit - J104- is bolted to the ABS hydraulic unit -
N55- and is located on the right in the engine compartment.

WARNING

Do not bend the brake lines in the area of the hydraulic unit!
AG. Volkswagen AG d
agen oes
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– Read out and note the existing
d byV control unit code. gu
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– Note or request radio
ut code on vehicles with coded radio if
ho eo
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necessary. ss a c
ce
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nl

– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Battery;

pt
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an

Disconnecting and connecting battery .

itte

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1.2 l TSI engines:

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– Remove pressure pipe and intake connecting pipe together

h re

with regulating flap control unit ⇒ Rep. gr. 24 ; Intake manifold;

hole

spec

Removing and installing regulating flap control unit - J808- .

es, in part or in w

t to the co

– Remove charge air hose ⇒ Rep. gr. 21 ; Charge air system;

Assembly overview - charge air hose connections .
rrectness of i

– Clamp off hose from coolant expansion tank and pull it off.
l purpos

1.9 l diesel engines:

– Unclip fuel hoses and coolant hoses from charge air pipe.
nform
mercia

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py by
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Prote AG.

30 Rep. gr.45 - Anti-lock brake system

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Unscrew bolt -1-.

– Release retaining clips -arrows-.
– Remove charge air pipe together with connecting hoses be‐
tween charge air cooler and intake manifold flap motor -
V157- .
– Remove intake manifold flap motor - V157- ⇒ Rep. gr. 23 ;
Intake manifold; Removing and installing intake manifold flap
motor - V157- .
Engine code BJB:
– Remove connecting pipe together with connecting hoses be‐
tween charge air cooler and turbocharger ⇒ Rep. gr. 21 ;
Charge air system; Assembly overview - charge air hose con‐
nections .
– Remove intake connecting pipe ⇒ enRep.
AG. Vgr.
olksw23
age;nIntake
AG do mani‐
fold; Assembly overview - intake
olkswagmanifold . es n
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2.0 l diesel engines: ir se nte
ho eo
ut
– Remove centre bulkhead ⇒ General plenum
ss
a chamber body ra
c
repairs, exterior; Rep. gr. 50 ; Plenum chamber bulkhead;

ce
e
nl

Removing and installing plenum chamber bulkhead .

pt
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an
itte

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– Remove connecting pipe between intake hose and turbo‐
erm

ab
charger.

ility
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wit
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– Remove toothed belt guard upper part.

h re
hole

spec
Diesel engines with diesel particulate filter:
es, in part or in w

t to the co
– Release particulate filter (do not remove) ⇒ Rep. gr. 26 ;
Emission control; Removing and installing particulate filter .

– Disconnect connector of exhaust gas pressure sensor 1 - rrectness of i

G450- -1-.
l purpos

– Unscrew bolt -2-.

nform
ercia

– Remove bracket -3- together with exhaust gas pressure sen‐

m

sor 1 - G450- , and lay it aside.

at
om

ion
c

– Remove nut -4-.

in t
or

his
ate

– Remove heat shield -5- upwards.

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for

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Cop py
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

4. Control unit and hydraulic unit 31

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Remove nut -2-.

– Remove cover for brake lines -1-.
Continued for all vehicles:

n AG. Volkswagen AG do
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– Release connector in direction of -arrow 1-.

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– Release connector in direction of -arrow 2-.

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– Apply brake pedal depressor - V.A.G 1869/2- .
ot p

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– Connect bleeder bottle hose to front left brake caliper bleeder

h re
hole

valve and rear left brake caliper bleeder valve and open bleed‐

spec
er valves.
es, in part or in w

t to the co
– Depress brake pedal at least 60 mm using brake pedal de‐
pressor - V.A.G 1869/2- .

rrectness of i
– Close front left and rear left bleeder valve.
l purpos

– Do not remove brake pedal depressor - V.A.G 1869/2- .

– Place sufficient lint-free cloths under the control unit and hy‐
nf
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draulic unit.
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or

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No brake fluid must get onto the contacts.

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Prote AG.

32 Rep. gr.45 - Anti-lock brake system

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– First identify the two brake master cylinder brake lines

-A and B- and unscrew from the hydraulic unit.
– Immediately seal brake lines and threaded holes with sealing
plugs - 1H0 698 311 A- .
– Identify brake lines (brake calipers) -1 to 4-, unscrew and seal.
Bolted retainer, Caddy 2011 ▶
– Turn hexagon fitted bolt out of retainer.
– Pull off ABS hydraulic unit - N55- with ABS control unit - J104-
and retainer sideways from damper rubbers of bracket and
turn upside down.
– Unbolt bracket from ABS hydraulic unit - N55- in engine com‐
. Volkswagen AG
partment and remove. swa
gen AG does
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Continuation for all vehicles edb ara
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– Remove ABS hydraulic unit - N55- with ABS control
aut unit - ra
c
J104- upwards out of dampers. ss

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Installing

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Install in reverse order, noting the following:

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Note
hole

spec
es, in part or in w

♦ Do not remove sealing plugs - 1H0 698 311 A- from the new

t to the co
hydraulic unit until the respective brake lines are about to be
installed.

rrectness of i
♦ If the sealing plugs - 1H0 698 311 A- are removed too early
from the hydraulic unit, brake fluid can escape, and it can then
l purpos

no longer be guaranteed that the unit can be sufficiently filled

and bled.

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o
♦ When installing, ensure that rubber dampers are not pressed

rm
m

out of bracket.

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– Before installing bracket of ABS hydraulic unit - N55- into
te

sd
a

bracket, spray rubber dampers with silicone lubricant - D 007

iv

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000 A2- .
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t.
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– Using assembly tool - V.A.G 1410/8- , carefully fit brake lines.
Co
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– Tighten brake lines using special tool assembly.
op Vo
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– Remove brake pedal actuator - V.A.G 1869/2- .
AG.

– Bleed brake system ⇒ page 99 .

– Code radio.
– Code ABS control unit - J104- using ⇒ Vehicle diagnostic test‐
er.
To do this, basic setting of steering angle sender - G85- , lateral
acceleration sender - G200- and brake pressure sender - G201-
must be performed.
Torque settings

Component Torque setting

Control unit to hydraulic unit 5.5 Nm
Hexagon bolt of hydraulic unit to bracket 8 Nm
Brake lines to ABS unit, M10 x 1 14 Nm
Brake lines to ABS unit, M12 x 1 14 Nm

4. Control unit and hydraulic unit 33

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

Component Torque setting

Securing bolt for bracket of exhaust gas pressure sen‐ 3 Nm
sor 1 - G450-
Nuts for heat shield of particulate filter 10 Nm

4.7 Separating and assembling ABS control

unit - J104- and ABS hydraulic unit -
N55-
Disconnecting
– Place hydraulic unit with control unit downwards on a clean
flat level surface.
– Unscrew Torx bolt -arrows- from hydraulic pump.

WARNING

Hydraulic pump must not be separated from hydraulic unit.

AG. Volkswagen AG d
agen oes
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– The hydraulic pump must therefore be secured onto the hy‐

rm

ab
pe

ility

draulic unit with the red retainer -1- from the repair kit and two
ot

sealing plugs -2-.

wit
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h re
hole

spec
es, in part or in w

t to the co
rrectness of i
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nform
mercia

– Carefully lift hydraulic unit with hydraulic pump at joint -1- up‐
a
com

tio

wards off control unit.

n in
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Cop py
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Prote AG.

34 Rep. gr.45 - Anti-lock brake system

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

When pulling off the control unit, ensure that the hydraulic unit
contact pins are not canted against the control unit solenoids.
Item 2 adapter for pump motor.
– Cover control unit solenoids with a lint-free cloth.
After separating control unit and hydraulic unit, use transport pro‐
tection for contact pins.
Assembling

WARNING

Severe shocks (e.g. dropping, impact) may destroy the control

unit. Control unit must not then be used. AG. Volkswagen A
agen G do
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♦ Before the new control unit can be installed,
horis the pump motor tee
adapter must be inserted to stop and must
au engage. Make sure
t or
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not to damage the adapter guide. ss

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♦ The adapter supplied as a spare part for the control unit can

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only be engaged once and then cannot be removed.
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♦ The white paste on the bottom of the control unit serves as
ot

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sealant and must not be removed.

h re
hole

♦ Make sure not to touch any contact surfaces on the adapter,

spec
pressure sensor and control unit as well as the silicone gel and
es, in part or in w

t to the co
the sealing components by hand or with objects to prevent
them from being dirty or damaged.
– Press adapter into adapter guide to stop; it must then be en‐

rrectness of i
gaged.
l purpos

– Without canting it, place control unit onto hydraulic unit.

– Bolt hydraulic unit and control unit with enclosed, new Torx

nform
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bolts.
m

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tion in
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Note
thi
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♦ A new control unit may be mounted on an existing hydraulic

um
fo

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unit max. twice to guarantee impermeability of the elastic seal.

n

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♦ A control unit which has already been operated in a vehicle
t. C rig
gh ht
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must not be installed a second time. p by
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cted agen
Prote AG.

4.8 Connecting brake lines to hydraulic unit

On tandem brake master cylinder:
A - Primary piston circuit of brake master cylinder to hydraulic unit.
- Identification: ∅ 6.5mm and flare nut with thread M12x1.
B - Secondary piston circuit of brake master cylinder to hydraulic
unit.
- Identification: ∅ 6.5mm and flare nut with thread M12x1.
1 - From hydraulic unit to front left brake caliper
3 - Hydraulic unit to rear right brake caliper
4 - From hydraulic unit to rear left brake caliper

4. Control unit and hydraulic unit 35

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

On hydraulic unit:
A - From hydraulic unit to primary piston circuit of brake master
cylinder.
- Identification: ∅ 6.5 mm and flare nut with long thread M12x1.
B - From hydraulic unit to secondary piston circuit of brake master
cylinder.
- Identification: ∅ 6.5 mm and flare nut with long thread M12x1.
1 - From hydraulic unit to front left brake caliper
- Identification: ∅ 5.25 mm and flare nut with short thread M12x1.
2 - From hydraulic unit to front right brake caliper.
- Identification: ∅ 5.25 mm and flare nut with thread M10x1.
3 - Hydraulic unit to rear right brake caliper
- Identification: ∅ 5.25 mm and flare nut with thread M10x1.
4 - From hydraulic unit to rear left brake caliper
- Identification: ∅ 5.25 mm and flare nut with short thread M12x1.

AG. Volkswagen AG d
agen oes
olksw not
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nl

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erm

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ility
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wit
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h re
hole

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es, in part or in w

t to the co
rrectness of i
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Cop py
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cted agen
Prote AG.

36 Rep. gr.45 - Anti-lock brake system

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

5 Sensors
⇒ “5.1 Assembly overview - speed sensor on front axle”,
page 37
⇒ “5.2 Removing and installing speed sensor on front axle”, page
38
⇒ “5.3 Assembly overview - speed sensor on rear axle”,
page 38
⇒ “5.4 Removing and installing speed sensor on rear axle”, page
39 en AG. V
olkswagen AG
ag does
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⇒ “5.5 Removing and installing
yV ESP sensor unit G419 ”,ot gua
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page 39 rise ran
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⇒ “5.6 Removing
ss aand installing steering angle sender G85 ”, page r ac
40

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nl

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5.1 Assembly overview - speed sensor on front axle
itte

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erm

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ility
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1 - ABS speed sensor

h re
hole

❑ Before inserting sensor,

spec
clean hole inner surface
es, in part or in w

t to the co
and coat with high-tem‐
perature paste
G 052 112 A3.

rrectness of i
❑ Renewing ⇒ page 38
l purpos

2 - Hexagon socket head bolt,

8 Nm nform
ercia

3 - Wheel bearing/wheel bear‐

ing unit
m

at
om

io

❑ ABS sensor ring is in‐

n
c

in t
r

stalled in wheel bearing

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ate

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4 - Drive shaft
p

cum
for

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Prote AG.

5. Sensors 37
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

5.2 Removing and installing speed sensor

on front axle
Removing
– Raise vehicle on lift.
– Separate connector -1- from speed sensor wire and from
speed sensor.
. Volkswagen AG
wa gen AG does
– Remove bolt -2- from wheel bearingVhousing.
olks not
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db ara
– Pull ABS speed sensor out ofowheel
ris
e
bearing housing. nte
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ut ra
Installing ss a c

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– Before inserting speed sensor, clean inner surface of hole and

pt
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coat speed sensor all around with high-temperature paste

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rm

G 052 112 A3.

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pe

ility
ot

– Insert speed sensor into hole in wheel bearing housing and

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, is n

tighten bolt to 8 Nm.

h re
hole

spec
– Connect speed sensor to speed sensor wire.
es, in part or in w

t to the co
5.3 Assembly overview - speed sensor on rear axle

rrectness of i
1 - ABS speed sensor
l purpos

❑ Before inserting sensor,

clean hole inner surface

nform
ercia

and coat with high-tem‐

perature paste
m

a
com

ti
G 052 112 A3.
on in
r
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❑ Renewing ⇒ page 39 thi

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2 - Hexagon socket head bolt,

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8 Nm
fo

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3 - Wheel bearing/wheel bear‐ Cop py
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ing unit opyri
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❑ ABS sensor ring is in‐ by c lksw

cted agen
stalled in wheel bearing Prote AG.

38 Rep. gr.45 - Anti-lock brake system

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

5.4 Removing and installing speed sensor

on rear axle
Removing
– Raise vehicle on lift.
– Separate connector -1- from speed sensor wire and from
speed sensor.
– Remove bolt -2- from wheel bearing housing.
– Pull ABS speed sensor out of wheel bearing housing.
Installing
– Before inserting speed sensor, clean inner surface of hole and
coat speed sensor all around with high-temperature paste
G 052 112 A3.
– Insert speed sensor into hole in wheel bearing housing and
tighten bolt to 8 Nm.
– Connect speed sensor to speed sensor wire.

5.5 Removing and installing ESP sensor

unit - G419-

Note
. Volkswagen AG
gen AG
♦ Not installed on vehicles
ksw with ABS up to modelesyear
not 2007
a o d
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♦ As of 2008, installed
or
ise in ABS control unit - J104- nte
th eo
au ra
c
ss
The lateral acceleration sender - G200- and the yaw rate sender
ce
e
nl

- G202- are installed together in one housing behind the glove

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box.
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erm

ab

After exchanging the ESP sensor unit - G419- , carry out basic
ility
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setting for lateral acceleration sender - G200- .

wit
, is n

h re
hole

spec

WARNING
es, in part or in w

t to the co

Severe shocks (e.g. dropping, impact) may destroy the ESP

sensor unit - G419- . The ESP sensor unit - G419- may not
then be used any further.
rrectness of i
l purpos

Removing
nf
ercia

– Remove glove compartment. ⇒ General body repairs, interior;

orm

Rep. gr. 68 ; Compartments, covers and trims

m

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om

n in
or c

thi
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by
cted agen
Prote AG.

5. Sensors 39
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Pull connector -1- off ESP sensor unit - G419- .

– Remove the two securing nuts -arrows-.
– Remove ESP sensor unit - G419- .
Installing
– Installation is carried out in reverse order.
When installing the ESP sensor unit, make sure it is correctly
seated in its bracket and is free of stress.

Note

Do not use the securing nuts to forcibly position

wage
n AG. VoESP
lkswagsensor
en AG unit.
doe
ks s no
Vol t gu
d by ara
– Tighten securing nuts toor9iseNm. nte
th eo
– Carry out basic setting
s au of lateral acceleration sender - G200- .
ra
c
s

ce
e
nl

Connect vehicle diagnostic tester and select function

pt
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an
⇒ page 14 .
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erm

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ility
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5.6 Removing and installing steering angle

wit
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h re
sender - G85-
hole

spec
es, in part or in w

The steering angle sender - G85- is located between the steering

t to the co
wheel and steering column switch.
Removing and installing

rrectness of i
⇒ Electrical system; Rep. gr. 94 ; Lights, bulbs, switches - exte‐
l purpos

rior; Steering column switch .

– Then carry out basic setting of steering angle sender - G85- .
nf
ercia

Connect vehicle diagnostic tester and select function

rm
m

⇒ page 14 .
atio
om

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Prote AG.

40 Rep. gr.45 - Anti-lock brake system

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

46 – Brakes - mechanism
1 Front brakes
⇒ “1.1 Assembly overview - front brake caliper FS III”,
page 41
⇒ “1.2 Removing and installing brake pads/linings”, page 43
⇒ “1.3 Removing and installing brake caliper”, page 46
⇒ “1.4 Assembly overview - front brake caliper FN 3”, page 48
⇒ “1.5 Removing and installing brake pads/linings”, page 50
⇒ “1.6 Removing and installing brake caliper”, page 53

1.1 Assembly overview - front brake caliper

FS III

Note

♦ After replacing brake pads, depress brake pedal firmly several

times with vehicle stationary so that the pads are properly
seated in their normal operating position.
♦ Use the brake filling and bleeding equipment - VAS 5234- to
draw off brake fluid from the brake fluid reservoir.
. Volkswagen AG
gen AG
♦ Before removing a brake caliper or disconnecting a brake a does
ksw not
Vol
hose, fit brake pedal depressor - V.A.G 1869/2- (when
ed
by doing gu
ara
this, release pressure in system). thoris nte
eo
au ra
c
ss

ce
le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

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t.
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Cop py
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rig ht
py by
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by lksw
cted agen
Prote AG.

1. Front brakes 41
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

1 - Hexagon/Torx bolt, 12 Nm
❑ M6 x 10 hexagon bolt re‐
vised to M6 x 12 Torx
bolt
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❑ Replace hexagon head lkswage es n
bolt with hexagon d by V head
o ot g
ua
bolt and Torx
o
ir se bolt with
ran
tee
Torx bolt.
au
th or
a
ss c
2 - Brake disc

ce
le
un

pt
❑ Internally ventilated

an
d
itte

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erm

❑ Always renew on both

ab
ility
sides of an axle.
ot p

wit
is n

❑ Remove brake caliper

h re
ole,

prior to removing.

spec
urposes, in part or in wh

3 - Cross-point/Torx bolt, 4 Nm

t to the co
4 - Brake pads
❑ With break pad wear in‐

rrectne
dicator.
❑ When wear reaches a

ss
predetermined limit (ap‐

o
cial p

f
prox 4 mm) warning

inform
lamp in dash panel in‐
mer

sert comes on.

atio
om

❑ Check thickness
n
c

i
or

⇒ Maintenance ; Book‐
thi
te

sd

let 39 .
iva

o
pr

❑ Always renew on both

um
r
fo

en
ng

sides of an axle.
t.
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op
❑ Removing and installing
C py
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gh
⇒ page 43
ht
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5 - Connector
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❑ Brake lining wear indi‐

cator
6 - Brake caliper
❑ Do not disconnect brake hose when changing pads.
❑ Removing and installing ⇒ page 46
❑ Repairing ⇒ page 86
7 - Guide pin, 30 Nm
8 - Cover
❑ Remove
9 - Brake hose with banjo union and banjo bolt, 35 Nm
❑ Removing and installing ⇒ page 115
10 - Guide pin, 30 Nm
11 - Cover
❑ Remove
12 - Bolt
13 - Holder
14 - Wheel bearing housing
❑ With integrated brake carrier.
15 - ABS speed sensor
❑ Before inserting sensor, clean hole inner surface and coat with high-temperature paste G 052 112 A3.

42 Rep. gr.46 - Brakes - mechanism

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

16 - Hexagon socket head bolt, 8 Nm

17 - Wheel bearing/wheel bearing unit
❑ ABS sensor ring is installed in wheel bearing
18 - Cover plate

1.2 Removing and installing brake pads/lin‐

ings agen
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olks ot g
Special tools and workshop
ed
byequipment required
V ua
ran
ris tee
♦ Torque wrench - aV.A.G
ut
ho 1331- or
ac
ss

ce
le
un

pt
an
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itte

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ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

♦ Piston resetting appliance - T10145-

nform
mercia

a
com

tion in
r
te o

thi
s
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cum
fo

en
ng

t.
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Cop py
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Removing

Note

Mark brake pads or linings when removing if they are to be

reused. Fit in same position when installing, or braking will be
uneven.

– Remove wheels.

1. Front brakes 43
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Disconnect connector -1- for brake pad wear indicator.

– Remove protective caps -arrows-.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
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rise nte
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nl

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ab
ility
ot p

wit
, is n

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hole

spec
– Loosen guide pins -arrows- and remove from brake caliper.
es, in part or in w

t to the co

– Remove brake caliper housing and secure with wire so that

the weight of the brake caliper does not stress or damage the
brake hose.
rrectness of i

– Take brake pads out of brake caliper.

l purpos

Cleaning:
nf
ercia

WARNING
rm
m

atio
om

Do not blow out brake system with compressed air as the re‐
n in
or c

sulting dust is dangerous to health!

thi
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cu
o

m
f

en
ng

– Thoroughly clean brake carrier and contact surfaces for brake

t.
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pads and remove corrosion. Cop py
t. rig
gh ht
yri
– Clean brake caliper. p by
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by lksw
cted agen
Prote AG.

Note

Use brake and clutch cleaner to clean the brake caliper.

Installing

Note

Before pressing piston back into cylinder with piston resetting tool,
draw off brake fluid from brake fluid reservoir. Otherwise, partic‐
ularly if reservoir has been topped up, fluid will overflow and cause
damage.

44 Rep. gr.46 - Brakes - mechanism

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Press back piston with piston resetting appliance - T10145- .

– Lightly grease guide surfaces on brake carrier with lithium
grease - G 052150 A2- .

– Insert inner brake pad (piston side) -1- and outer brake pad
-2- into brake caliper with retaining springs.
♦ Inner brake pad (piston side) with large 3-finger clip -1-.
♦ Outer brake pad with small 3-finger clip -2- (coloured black).

n AG. Volkswagen AG do
lkswage es n
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– First position brake caliperthwith brake pads at bottom -arrow-
o tee
or
of brake carrier. ss
au ac

ce
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nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
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at
om

ion
c

in t
or

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ate

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for

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ng

t.
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Cop py
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pyri by
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cted agen
Prote AG.

1. Front brakes 45
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Bolt brake caliper to brake carrier with both guide pins.

• Brake caliper stud must be positioned behind brake carrier
guide!
– Fit both protective caps.
– Reconnect connector for brake pad wear indicator.
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Fitting wheel .

Note

♦ After changing brake pads, firmly depress brake pedal several

times with vehicle stationary, so that the brake pads are prop‐
erly seated in their normal operating position.
♦ After changing brake pads/linings, check brake fluid level.

Specified torques:
Guide pin to brake carrier 30 Nm
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1.3 Removing and installing brake caliper olk ot g
byV ua
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ir se tee
Special tools and workshop equipment requiredautho
or
ac
ss
♦ Torque wrench - V.A.G 1331-

ce
le
un

pt
an
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itte

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ab
pe

ility
ot

wit
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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

♦ Brake pedal actuator - V.A.G 1869/2-

nform
mercia

a
com

tion in
r
te o

thi
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cum
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Prote AG.

Removing

Note

This procedure applies only to exchanging the brake caliper or

the following repair work on the brake caliper.

46 Rep. gr.46 - Brakes - mechanism

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Remove wheels.
– Separate connector for brake pad wear indicator.
– Connect bleeder bottle hose to brake caliper bleeder valve and
open bleeder valve.
– Apply brake pedal depressor - V.A.G 1869/2- .
. Volkswagen AG
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– Close bleeder valve and remove kbleeder bottle. does
swa
ol not
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– Disconnect brake hose. ised b ara
nte
r
tho eo
– Pull both caps out of sbearing
au bushes of brake caliper. ra
c
s
– Loosen both guide pins and remove from brake caliper.

ce
e
nl

pt
du

an
itte

– Pull brake caliper off brake carrier.

y li
erm

ab
ility
– Remove brake pads from brake caliper.
ot p

wit
, is n

Installing

h re
hole

spec
• The piston is pressed back.
es, in part or in w

t to the co
– Insert inner brake pad (piston side) -1- and outer brake pad
-2- into brake caliper with retaining springs.

rrectness of i
♦ Inner brake pad (piston side) with large 3-finger clip -1-.
l purpos

♦ Outer brake pad with small 3-finger clip -2- (coloured black).

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orm
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n in
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– First position brake caliper with brake pads at bottom -arrow-
yi Co
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of brake carrier. . C rig
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cted agen
Prote AG.

1. Front brakes 47
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Bolt brake caliper to brake carrier with both guide pins.

• Brake caliper stud must be positioned behind brake carrier
guide!
– Fit both protective caps.
– Screw brake hose onto brake caliper.
– Remove brake pedal depressor - V.A.G 1869/2- .
– Reconnect connector for brake pad wear indicator.
– Bleed brake system ⇒ page 99 .
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Fitting wheel .

Note

♦ Firmly depress brake pedal several times with vehicle station‐

ary so that the brake pads/linings are properly seated in their
normal operating position.
♦ Check brake fluid level.

Tightening torques:
Guide pin to brake carrier 30 Nm
Brake hose to brake caliper 35 Nm

1.4 Assembly overview - front brake caliper

FN 3 AG. Volkswagen AG d
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Note orise nte
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♦ After replacing brake pads, depress brake pedal firmly several s
ce
e

times with vehicle stationary so that the pads are properly

nl

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seated in their normal operating position. an

itte

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erm

ab
♦ Use the brake filling and bleeding equipment - VAS 5234- to ility
ot p

draw off brake fluid from the brake fluid reservoir. wit
, is n

h re

♦ Before removing a brake caliper or disconnecting a brake

hole

spec

hose, fit brake pedal depressor - V.A.G 1869/2- (when doing

es, in part or in w

this, release pressure in system).

t to the co
rrectness of i
l purpos

nf
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Prote AG.

48 Rep. gr.46 - Brakes - mechanism

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

1 - Cross-point/Torx bolt, 4 Nm
2 - Brake disc
❑ Internally ventilated
❑ Always renew on both
sides of an axle.
❑ Remove brake caliper
prior to removing.
3 - Brake pads
❑ With break pad wear in‐
dicator.
❑ When wear reaches a
predetermined limit (ap‐
prox 4 mm) warning
lamp in dash panel in‐
sert comes on.
❑ Check thickness
⇒ Maintenance ; Book‐
let 39 .
❑ Always renew on both
sides of an axle.
❑ Removing and installing
⇒ page 50
AG. Volkswagen AG d
4 - Retaining spring ksw
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❑ Insert into both holes in ed
by ara
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brake caliper. thoris eo
au ra
5 - Brake carrier ss c

ce
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un

❑ Bolt to wheel bearing

pt
an
d

housing.
itte

y li
erm

6 - Brake caliper ab
ility
ot p

❑ Do not disconnect brake wit

is n

h re
hose when changing
ole,

spec
pads.
urposes, in part or in wh

❑ Removing and installing

t to the co

⇒ page 53
❑ Repairing ⇒ page 86
rrectne

7 - Guide pin, 30 Nm
s

8 - Cover
s o
cial p

❑ Remove
inform
mer

9 - Brake hose with banjo union and banjo bolt, 35 Nm

atio
m

❑ Removing and installing ⇒ page 115

o

n
c

i
or

n thi
e

10 - Ribbed bolt, 190 Nm

t

sd
iva

o
r

❑ Clean if reusing.
p

cum
r
fo

en
ng

11 - Bolt
t.
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Cop py
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12 - Holder
rig
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co
13 - Wheel bearing housing
by lksw
cted agen
Prote AG.
❑ With bolted brake carrier
14 - ABS speed sensor
❑ Before inserting sensor, clean hole inner surface and coat with high-temperature paste G 052 112 A3.

1. Front brakes 49
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

15 - Hexagon socket head bolt, 8 Nm

16 - Cover plate
17 - Hexagon/Torx bolt, 12 Nm
❑ M6 x 10 hexagon bolt revised to M6 x 12 Torx bolt
❑ Replace hexagon head bolt with hexagon head bolt and Torx bolt with Torx bolt.
18 - Wheel bearing/wheel bearing unit
❑ ABS sensor ring is installed in wheel bearing

1.5 Removing and installing brake pads/lin‐

ings olkswage
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es n
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by ara
Special tools and workshop equipment requiredrised nte
ho eo
ut
♦ Torque wrench - V.A.G 1331- ss
a ra
c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectnes
♦ Piston resetting appliance - T10145-

s o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

Removing

Note

Mark brake pads or linings when removing if they are to be

reused. Fit in same position when installing, or braking will be
uneven.

– Remove wheels.

50 Rep. gr.46 - Brakes - mechanism

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Lever brake pad retaining spring out from brake caliper

-arrow- with a screwdriver and remove.

– Disconnect connector -1- for brake pad wear indicator.

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
o
– Remove protectiveaucaps -arrows-.
th or
ac
ss
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Front brakes 51
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Loosen guide pins -arrows- and remove from brake caliper.

– Remove brake caliper housing and secure with wire so that
the weight of the brake caliper does not stress or damage the
brake hose.
– Take brake pad out of brake caliper or from brake carrier.
Cleaning:

AG. Volkswagen AG d
WARNING lksw
agen oes
not
Vo gu
d by ara
e
Do not blow out brake system with horis compressed air as the re‐ nte
eo
sulting dust is dangerous to health!
s aut ra
c
s

ce
le
un

pt
an
d

– Thoroughly clean brake carrier and contact surfaces for brake

itte

y li
rm

pads and remove corrosion.

ab
pe

ility
ot

– Clean brake caliper, in particular the bonding surface for the

wit
, is n

brake pad. It must be free of adhesive and grease residues.

h re
hole

spec
es, in part or in w

t to the co
Note

Use brake and clutch cleaner to clean the brake caliper.

rrectness of i
l purpos

Installing

nform
ercia

Note
m

a
com

tio
Before pressing piston back into cylinder with piston resetting tool,
n in
r

draw off brake fluid from brake fluid reservoir. Otherwise, partic‐
te o

thi
ularly if reservoir has been topped up, fluid will overflow and cause
s
iva

do

damage.
r
rp

cum
fo

en
ng

t.
yi Co
op py
– Press back piston with piston resetting appliance - T10145- . t. C rig
gh ht
pyri by
Vo
– Lightly grease guide surfaces on brake carrier with lithium
o
by c lksw
cted agen
grease - G 052150 A2- . Prote AG.

– Pull protective foil off outer brake pad backplate.

– Fit outer brake pad to brake carrier.
– Insert inner brake pad with retaining spring in brake caliper
(piston).
When positioning the brake caliper, ensure that the brake pad
does not stick to the brake caliper housing before it is positioned
correctly.
Do not damage adhesive surface.

52 Rep. gr.46 - Brakes - mechanism

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Bolt brake caliper to brake carrier with both guide pins.

– Fit both protective caps.
– Insert retaining spring into brake caliper.
– Reconnect connector for brake pad wear indicator.
AG. Volkswagen AG d
– Fit wheels. ksw
agen oes
not
Vol
y gu
Specified torque of wheelisbolts
ed b ⇒ Running gear, axles, steering;aran
Rep. gr. 44 ; Fitting wheel
ut
ho .
r tee
or
a ac
ss

ce
e
nl

pt
Note
du

an
itte

y li
erm

ab
♦ After changing brake pads, firmly depress brake pedal several

ility
ot p

times with vehicle stationary, so that the brake pads are prop‐

wit
, is n

erly seated in their normal operating position.

h re
hole

spec
♦ After changing brake pads/linings, check brake fluid level.
es, in part or in w

t to the co
Specified torques:
Guide pin to brake carrier 30 Nm

rrectness of i
l purpos

1.6 Removing and installing brake caliper

nform
ercia

Special tools and workshop equipment required

m

♦ Torque wrench - V.A.G 1331-

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

♦ Brake pedal actuator - V.A.G 1869/2-

Removing

Note

This procedure applies only to exchanging the brake caliper or

the following repair work on the brake caliper.

1. Front brakes 53
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Remove wheels.
– Lever brake pad retaining spring out from brake caliper with a
screwdriver and remove.
– Separate connector for brake pad wear indicator.
– Connect bleeder bottle hose to brake caliper bleeder valve and
open bleeder valve.
– Apply brake pedal depressor - V.A.G 1869/2- .
– Close bleeder valve and remove bleeder bottle.
– Disconnect brake hose.
– Pull both caps out of bearing bushes of brake caliper.
– Loosen both guide pins and remove from brake caliper.
olkswagen AG
en AG. V
– Pull brake caliper off brake carrier.
olks
wag does
not
V gu
by ara
– Remove brake pads from
ris brake
ed caliper. nte
tho eo
Installing s au ra
c
s

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le

• The piston is pressed back.

un

pt
an
d
itte

y li
• Outer brake pad is seated on brake carrier.
rm

ab
pe

ility
– Insert inner brake pad with retaining spring in brake caliper
ot

wit
, is n

(piston).

h re
hole

When positioning the brake caliper, ensure that the brake pad

spec
es, in part or in w

does not stick to the brake caliper housing before it is positioned

t to the co
correctly.
Do not damage adhesive surface. rrectness of i
– Bolt brake caliper to brake carrier with both guide pins.
l purpos

– Fit both protective caps.

– Screw brake hose onto brake caliper.
nform
ercia

– Remove brake pedal depressor - V.A.G 1869/2- .

m

a
com

tio

– Insert retaining spring into brake caliper.

n in
r
te o

thi

– Reconnect connector for brake pad wear indicator.

s
iva

do
r
rp

cum

– Bleed brake system ⇒ page 99 .

fo

en
ng

t.
yi Co
– Fit wheels. . Cop py
rig
ht ht
rig
Specified torque of wheel bolts ⇒ Running gear, axles, steering; py by
o Vo
Rep. gr. 44 ; Fitting wheel .
by c lksw
cted agen
Prote AG.

Note

♦ Firmly depress brake pedal several times with vehicle station‐

ary so that the brake pads/linings are properly seated in their
normal operating position.
♦ Check brake fluid level.

Tightening torques:
Guide pin to brake carrier 30 Nm
Brake hose to brake caliper 35 Nm

54 Rep. gr.46 - Brakes - mechanism

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

2 Rear brakes
⇒ “2.1 Assembly overview - rear brake CI 38”, page 55
⇒ “2.2 Removing and installing brake caliper”, page 57
⇒ “2.3 Removing and installing brake pads/linings”, page 59
⇒ “2.4 Assembly overview - rear brake CII 41”, page 61
⇒ “2.5 Installation instructions for brake carrier CII 41”,
page 63
⇒ “2.6 Removing and installing brake caliper”, page 64
⇒ “2.7 Removing and installing brake pads/linings”, page 65
⇒ “2.8 Assembly overview - rear brake CII 41 (all-wheel drive)”,
page 68
⇒ “2.9 Assembly overview - rear brakes, Bosch BIR, Caddy 2011
▶”, page 71
⇒ “2.10 Removing and installing brake caliper”, page 72
⇒ “2.11 Removing and installing brake pads/linings”, page 74

2.1 Assembly overview - rear brake CI 38

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agen oes
lksw not
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Every time after changing pads, firmly depress brake pedal
h
♦ aut ra
several times with vehicle stationary. This process ensures
ss c ce
le

that brake pads are properly seated in their normal operating

un

pt

position.
an
d
itte

y li
rm

ab

♦ Use the brake filling and bleeding equipment - VAS 5234- to

pe

ility

extract brake fluid from the brake fluid reservoir.

ot

wit
, is n

h re

♦ Fit brake pedal depressor - V.A.G 1869/2- before removing a

hole

spec

brake caliper or disconnecting a brake hose. After that, open

es, in part or in w

brake system to release pressure.

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

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r
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cum
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
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o
by c lksw
cted agen
Prote AG.

2. Rear brakes 55
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

1 - Dual-combi bolt
❑ Renew each time after
removing
❑ Torque setting 90 Nm
and turn 90° further
2 - Hexagon socket-head bolt
❑ Threaded connection
for speed sensor
❑ Tightening torque 8 Nm
3 - Rear left speed sensor -
G46- for ABS
❑ Before inserting sensor,
clean hole inner surface
and coat with high-tem‐
perature paste
G 052 112 A3.
4 - Axle assembly with stub
axle
❑ Various versions ⇒
Running gear, axles,
steering; Rep. gr. 42 ;
Repairing rear wheel
suspension (front-wheel
drive)
Volkswagen AG
5 - Cover plate agen
AG. does
olksw not
❑ Various versions ⇒ ed by V gu
ara
Running gear, axles,
ho
ris nte
eo
steering; Rep. agr.
ut 42 ; ra
c
Repairing rear
ss wheel
ce
e

suspension (front-wheel
nl

pt
du

an

drive)
itte

y li
erm

ab

6 - Bolt
ility
ot p

❑ Various versions ⇒
wit
, is n

h re

Running gear, axles,

hole

steering; Rep. gr. 42 ;

spec

Repairing rear wheel suspension (front-wheel drive)

es, in part or in w

t to the co

7 - Wheel bearing/wheel bearing unit

❑ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Repairing rear wheel suspension (front-wheel drive)
rrectness of i

8 - Brake disc
l purpos

❑ When worn, renew on both sides of axle.

❑ Remove brake caliper prior to removing.
nform
ercia

9 - Torx bolt
m

at
om

❑ Threaded connection for brake disc

ion
c

in t
r

❑ Tightening torque 9 Nm
o

his
ate

do
riv

10 - Dust cap
p

cum
or

❑ Renew each time after removal ⇒ Running gear, axles, steering; Rep. gr. 42 ; Repairing rear suspension
f

en
ng

t.
yi
(front-wheel drive) .
Co
Cop py
t. rig
gh
11 - Bolt
ht
pyri by
Vo
o
by c lksw
❑ Renew each time after removal ⇒ Running gear, axles, steering; Rep. gr. 42 ; Repairing rear suspension
Prote
cted agen
(front-wheel drive) .
AG.

12 - Brake pads
❑ Check thickness ⇒ Maintenance ; Booklet 39 .
❑ Always renew on both sides of an axle.
❑ Removing and installing ⇒ page 59

56 Rep. gr.46 - Brakes - mechanism

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

13 - Brake carrier with guide pins and protective cover AG. Volkswagen AG d
agen
❑ Supplied as a complete genuine part, pre-assembled Volksw with sufficient amount
oes
not of grease on guide pins.
gu
by ara
❑ If protective covers or guide pins are damaged,
rised install repair kit and use lubricant
nte sachet supplied to
lubricate guide pins utho eo
ra ac
ss
14 - Brake caliper

ce
le
un

pt
❑ Do not disconnect brake hose when changing pads.

an
d
itte

y li
❑ Removing and installing ⇒ page 57

erm

ab
ility
ot p
❑ Repairing ⇒ page 93

wit
❑ Adjust handbrake cable first after repairing or renewing. is n

h re
ole,

spec
❑ Adjusting handbrake ⇒ page 81 .
urposes, in part or in wh

t to the co
15 - Hexagon bolt
❑ Self-locking
❑ Renew each time after removing

rrectne
❑ Tightening torque 35 Nm

ss
16 - Brake line

o
cial p

f i
❑ Tightening torque 14 Nm

nform
mer

17 - ABS speed sensor wire

atio
om

n
c

18 - Handbrake cable

i
or

n thi
e

❑ Removing and installing ⇒ page 77

t

sd
iva

o
pr

c
❑ Adjusting handbrake ⇒ page 81 .

um
r
fo

en
ng

t.
yi
19 - Brake hose
Co
Cop py
t.
❑ Removing and installing ⇒ page 115
rig
gh ht
pyri by
Vo
o
by c
20 - Hose retainer
lksw
cted agen
Prote AG.

2.2 Removing and installing brake caliper

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

2. Rear brakes 57
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

♦ Brake pedal actuator - V.A.G 1869/2- AG. Volkswagen AG d

agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
Removing

rrectne
Note

ss o
cial p

f in
The described procedure applies only to exchanging the brake

form
mer

caliper or the following repair work on the brake caliper.

atio
om

n
c

– Remove rear wheel.

i
or

n thi
te

sd
a

– Press back lever on brake caliper -4- in direction of arrow and

iv

o
pr

c
detach handbrake cable -1-.

um
r
fo

en
ng

t.
yi
– Compress locking lugs -2- together and pull handbrake cable
Co
op py
out of bracket on brake caliper. t. C rig
gh ht
pyri by
Vo
– Release electrical connector and separate it from rear left
o
by c lksw
cted agen
speed sensor - G46- for ABS. Prote AG.

– Take line -3- out of brake caliper bracket.

– Connect bleeder bottle hose to brake caliper bleeder valve and
open bleeder valve.
– Install brake pedal depressor - V.A.G 1869/2- in vehicle.
– Close bleeder valve and remove bleeder bottle.

58 Rep. gr.46 - Brakes - mechanism

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Unscrew brake line.

– Remove both securing bolts from brake caliper; when doing
this, counterhold on guide pin.
– Pull brake caliper off brake carrier.
Installing
• The piston is pressed back.
• The brake pads are seated on the brake carrier.
– Secure brake caliper to brake carrier with new self-locking
bolts. Specified torque is ⇒ Item 15 (page 57) .
– Reconnect brake line to brake caliper. Specified torque is
⇒ Item 16 (page 57) .
– Reconnect electrical connector of rear left speed sensor -
G46- for ABS. Secure line in retainer on brake caliper.
– Clip handbrake cable into bracket on brake caliper. Hook
handbrake cable into handbrake lever.
– Bleed brake system ⇒ page 99 .
– Adjust handbrake ⇒ page 81 .
– Install rear wheel. agen
AG. Volkswagen AG d
oes
olksw not
V
Specified torque of wheel bolts ed by⇒ Running gear, axles, steering;guar
an
Rep. gr. 44 ; Fitting wheelhor.is tee
ut or
a ac
ss
ce
le

Note
un

pt
an
d
itte

y li
rm

ab
♦ Every time after changing pads, firmly depress brake pedal
pe

ility
several times with vehicle stationary. This process ensures
ot

wit
, is n

that brake pads are properly seated in their normal operating

h re

position.
hole

spec

♦ Check brake fluid level in brake fluid reservoir each time brake
es, in part or in w

t to the co

pads are renewed.

rrectness of i

2.3 Removing and installing brake pads/lin‐

l purpos

ings
Special tools and workshop equipment required
nform
ercia

♦ Torque wrench - V.A.G 1331-

m

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2. Rear brakes 59
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

♦ Resetting and removal tool - T 10165-

Removing

Note

Mark reusable brake pads/linings when removing. Reinstall brake

pads/linings in the same location to counteract an uneven brak‐
ing.

– Remove wheels.
– Remove securing bolts from brake caliper; to do this, coun‐
terhold on guide pin.
– Take off brake caliper and secure it to body so that its weight
does not stress or damage brake hose.
– Take brake pads out of brake carrier.
olkswagen AG
en AG. V
Cleaning brake system: olkswag does
not
yV gu
db ara
rise nte
tho
WARNING eo
s au ra
c
s
ce
le

Do not blow out brake system with compressed air. The re‐
un

pt
an

sulting dust constitutes a health hazard!

d
itte

y li
erm

ab
ility
ot p

wit

– Thoroughly clean contact surfaces for brake pads on brake

is n

h re

carrier to remove brake dust and corrosion.

ole,

spec
urposes, in part or in wh

– Clean bonding surfaces of brake caliper. They must be free of

t to the co

adhesive material and grease.

rrectne

Note

Clean brake caliper only with methylated spirits.

ss o
cial p

f inform

Installing
mer

atio
om

n
c

Note
i
or

n thi
te

sd
iva

Before pressing the brake piston back, draw off some brake fluid
pr

cum
r
fo

from the reservoir. A brake fluid reservoir overflow may cause

en
ng

t.
damages when the brake piston is pressed back. For this pur‐
yi Co
op
pose, use the brake filling and bleeding equipment - VAS 5234-
C py
t. rig
gh
with the corresponding bleeder bottle.
ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

60 Rep. gr.46 - Brakes - mechanism

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Position resetting and removal tool - T 10165 - on brake caliper

as shown in illustration.
– Screw in brake piston by turning thumb wheel of resetting and
removal appliance - T 10165 - clockwise. Do not damage pro‐
tective cover when doing this.
– To aid screwing in, use special tool T10165/1.

Note

If pistons are difficult to move, an open-end spanner »AF 13« can

be used on intended flats -arrow A-.

– Pull protective film off backing plates for brake pads.

– Insert brake pads into brake carrier.
– Position brake caliper.

Note

When positioning the brake caliper, ensure that the brake pads
do not stick to the brake caliper before it is positioned correctly.
n AG. Volkswagen AG do
wage
– Secure brake caliper with yV
onew self-locking bolts. Specified
lks es n
ot g tor‐
que is ⇒ Item 15 (pageir se
d 57) .
b ua
ran
o tee
h
– Install wheels.s aut or
ac
s
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
ce
le
un

pt

Rep. gr. 44 ; Fitting wheel .

an
d
itte

y li
rm

ab
pe

ility
ot

Note
wit
, is n

h re
hole

♦ Every time after changing pads, firmly depress brake pedal

spec

several times with vehicle stationary. This process ensures

es, in part or in w

t to the co

that brake pads are properly seated in their normal operating

position.
♦ Check brake fluid level in brake fluid reservoir each time brake
rrectness of i

pads are renewed.

l purpos

2.4 Assembly overview - rear brake CII 41

nform
mercia

a
com

tion in

Note
r
te o

thi
s
iva

do

♦ Every time after changing pads, firmly depress brake pedal

r
rp

cum

several times with vehicle stationary. This process ensures

fo

en
g

that brake pads are properly seated in their normal operating

n

t.
yi Co
op
position. C py
t. rig
gh ht
yri
♦ Use the brake filling and bleeding equipment - VAS 5234- to
p by
co Vo
by lksw
extract brake fluid from the brake fluid reservoir. Prote
cted AG.
agen

♦ Fit brake pedal depressor - V.A.G 1869/2- before removing a

brake caliper or disconnecting a brake hose. After that, open
brake system to release pressure.

2. Rear brakes 61
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018
AG. Volkswagen AG d
agen oes
1 - Dual-combi bolt olksw not
y V gu
d b ara
❑ Renew each time after orise nte
eo
removing auth
ra
ss c
❑ Torque setting 90 Nm

ce
e
nl
and turn 90° further

pt
du

an
itte

y li
2 - Hexagon socket-head bolt

erm

ab
ility
ot p
❑ Threaded connection

wit
for speed sensor

, is n

h re
hole
❑ Tightening torque 8 Nm

spec
es, in part or in w
3 - Rear left speed sensor -

t to the co
G46- for ABS
❑ Before inserting sensor,
clean hole inner surface

rrectness of i
and coat with high-tem‐
l purpos

perature paste
G 052 112 A3.

nf
ercia

4 - Axle assembly with stub

or
axle

m
m

atio
m

❑ Various versions ⇒
o

n in
c

Running gear, axles,

or

thi
e

steering; Rep. gr. 42 ;

t

sd
iva

Repairing rear wheel

o
r
rp

cu
suspension (front-wheel
o

m
f

en
ng

drive)
t.
yi Co
Cop py
t. rig
5 - Cover plate opyri
gh by
Vo
ht

❑ Various versions ⇒
c by lksw
cted agen
Running gear, axles, Prote AG.
steering; Rep. gr. 42 ;
Repairing rear wheel
suspension (front-wheel
drive)
6 - Bolt
❑ Various versions ⇒
Running gear, axles,
steering; Rep. gr. 42 ;
Repairing rear wheel suspension (front-wheel drive)
7 - Wheel bearing/wheel bearing unit
❑ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Repairing rear wheel suspension (front-wheel drive)
8 - Brake disc
❑ When worn, renew on both sides of axle.
❑ Remove brake caliper and brake carrier prior to removing.
9 - Torx bolt
❑ Threaded connection for brake disc
❑ Tightening torque 9 Nm
10 - Dust cap
❑ Renew each time after removal ⇒ Running gear, axles, steering; Rep. gr. 42 ; Repairing rear suspension
(front-wheel drive) .
11 - Bolt
❑ Renew each time after removal ⇒ Running gear, axles, steering; Rep. gr. 42 ; Repairing rear suspension
(front-wheel drive) .
12 - Brake pads
❑ Check thickness ⇒ Maintenance ; Booklet 39 .
❑ Always renew on both sides of an axle.
❑ Removing and installing ⇒ page 65

62 Rep. gr.46 - Brakes - mechanism

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

13 - Backplate with different guide pins and protective caps

❑ Supplied as a complete genuine part, pre-assembled with sufficient amount of grease on guide pins.
❑ If protective covers or guide pins are damaged, install repair kit and use lubricant sachet supplied to
lubricate guide pins
❑ Installation instructions ⇒ page 63
14 - Pad retainer
❑ Always renew when changing pads.
15 - Brake caliper
❑ Do not disconnect brake hose when changing pads.
❑ Removing and installing ⇒ page 64
❑ Repairing ⇒ page 93
❑ Adjust handbrake cable first after repairing or renewing.
❑ Adjusting handbrake ⇒ page 81 .
16 - Brake line
❑ Tightening torque 14 Nm
17 - ABS speed sensor wire
18 - Handbrake cable
❑ Removing and installing ⇒ page 77
❑ Adjusting handbrake ⇒ page 81 .
19 - Brake hose
❑ Removing and installing ⇒ page 115
20 - Hexagon bolt
❑ Self-locking
❑ Renew each time after removing
❑ Tightening torque 35 Nm
21 - Brake hose retainer

AG. Volkswagen AG d
agen oes
lksw not
2.5 Installation instructions for brake carrier Vo gu
by ara
d
ise nte
CII 41 author eo
ra
ss c ce
le
un

pt

Note
an
d
itte

y li
rm

ab
pe

♦ If protective covers or guide pins are damaged, install availa‐

ility
ot

ble repair kit.

wit
, is n

h re

♦ Use lubricant sachet supplied to lubricate guide pins.

hole

spec
es, in part or in w

t to the co

Installation instructions:
1- Shorter guide pin with steps -arrows-, leading side
rrectness of i

2- Longer guide pin, phasing out

l purpos

3- Balance weight, phasing out

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o

63
c by lksw
cted agen
Prote AG. 2. Rear brakes
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

2.6 Removing and installing brake caliper

Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

♦ Brake pedal actuator - V.A.G 1869/2-

Removing

n AG. Volkswagen AG do
Note
lkswage es n
o ot g
byV ua
ed ran
The describedhprocedure
oris applies only to exchanging the brake tee
caliper or the aufollowing repair work on the brake caliper.
t or
ac
ss
ce
e
nl

pt

– Remove wheels.
du

an
itte

y li

– Press back lever on brake caliper -4- in direction of arrow and

erm

ab
ility

detach handbrake cable -1-.

ot p

wit
, is n

– Compress locking lugs -2- together and pull handbrake cable

h re
hole

out of bracket on brake caliper.

spec
es, in part or in w

– Release electrical connector and separate it from rear left

t to the co

speed sensor - G46- for ABS.

– Take line -3- out of brake caliper bracket.
rrectness of i

– Connect bleeder bottle hose to brake caliper bleeder valve and

l purpos

open bleeder valve.

– Install brake pedal depressor - V.A.G 1869/2- in vehicle.
nf
ercia

– Close bleeder valve and remove bleeder bottle.

rm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

64 Rep. gr.46 - Brakes - mechanism

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Unscrew brake line.

– Remove both securing bolts from brake caliper; when doing
this, counterhold on guide pin.
– Pull brake caliper off brake carrier.
Installing
• The piston is pressed back.
• The brake pads are seated in the pad retainers on the brake
carrier. wage
n AG. Volkswagen AG do
e ks s no
Vol t gu
– Secure brake caliper to brake carrier d bwith new self-locking
y ara
bolts. Specified torque is ⇒ Itemh20
rise(page 63) . nte
o t eo
au ra
– Reconnect brake line to brake
ss caliper. Specified torque is c
⇒ Item 20 (page 63) .

ce
e
nl

pt
du

an
itte

– Reconnect electrical connector of rear left speed sensor -

y li
erm

ab
G46- for ABS. Secure line in retainer on brake caliper.

ility
ot p

wit
– Clip handbrake cable into bracket on brake caliper. Hook
, is n

h re
handbrake cable into handbrake lever.
hole

spec
– Bleed brake system ⇒ page 99 .
es, in part or in w

t to the co
– Adjust handbrake ⇒ page 81 .
– Install rear wheel.

rrectness of i
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
l purpos

Rep. gr. 44 ; Fitting wheel .

nf
ercia

o
Note

rm
m

atio
om

♦ Every time after changing pads, firmly depress brake pedal

n in
or c

several times with vehicle stationary. This process ensures

thi
te

sd
a

that brake pads are properly seated in their normal operating

iv

o
r

position.
rp

cu
o

m
f

en
ng

t.
♦ Check brake fluid level in brake fluid reservoir each time brake
yi Co
op
pads are renewed.
C py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
2.7 Removing and installing brake pads/lin‐
AG.

ings
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

2. Rear brakes 65
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

♦ Resetting and removal tool - T 10165-

Removing

Note

Mark reusable brake pads/linings when removing. Reinstall brake

pads/linings in the same location to counteract an uneven brak‐
ing.

– Remove wheels.
– Remove securing bolts from brake caliper; to do this, coun‐
terhold on guide pin.
– Take off brake caliper and secure it to body sowthat
agen its weight
AG. Volkswagen AG d
oes
does not stress or damage brake hose. y Volks not
g b ua
ed ran
oris tee
th or
au ac
ss
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

66 Rep. gr.46 - Brakes - mechanism

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Take brake pads and pad retainers -arrows- out of brake car‐
rier.
Cleaning the brake system

WARNING

Do not blow out brake system with compressed air. The re‐
sulting dust constitutes a health hazard!

– Thoroughly clean contact surfaces for brake pad retainers on

brake carrier to remove brake dust and corrosion.
– Clean brake caliper.

Note

Clean brake caliper only with methylated spirits.

Installing

Note

Before pressing the brake piston back, draw off some brake fluid
from the reservoir. A brake fluid reservoir overflow may cause
damages when the brake piston is pressed back. For this pur‐
pose, use the brake filling and bleeding equipment - VAS 5234-
with the corresponding bleeder bottle.
n AG. Volkswagen AG do
lkswage es n
Vo ot g
– Position resetting andedremoval tool - T 10165 - on brake caliper
by ua
ran
as shown in illustration.
horis tee
ut or
a ac
– Screw in brakess piston by turning thumb wheel of resetting and
removal appliance - T 10165 - clockwise. Do not damage pro‐
ce
le
un

pt

tective cover when doing this.

an
d
itte

y li
erm

ab

– To aid screwing in, use special tool T10165/1.

ility
ot p

wit
is n

h re
ole,

Note
spec
urposes, in part or in wh

t to the co

If pistons are difficult to move, an open-end spanner »AF 13« can

be used on intended flats -arrow A-.
rrectne

– Insert pad retainers -arrows- and brake pads into brake carrier.
ss o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

2. Rear brakes 67
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Ensure that brake pads are seated correctly in pad retainers

-arrows-.
– Position brake caliper.
– Secure brake caliper with new self-locking bolts. Specified tor‐
que is ⇒ Item 20 (page 63) .
– Install wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Fitting wheel .
AG. Volkswagen AG d
agen oes
Note olksw not
V gu
d by ara
ise nte
or
♦ Every time after changing pads, firmly depress brake
aut
h pedal eo
ra
several times with vehicle stationary. This process
ss ensures c
that brake pads are properly seated in their normal operating

ce
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un

pt
position.

an
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rm

ab
♦ Check brake fluid level in brake fluid reservoir each time brake
pe

ility
pads are renewed.
ot

wit
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h re
hole

spec
2.8 Assembly overview - rear brake CII 41
es, in part or in w

t to the co
(all-wheel drive)

rrectness of i
Note
l purpos

♦ Every time after changing pads, firmly depress brake pedal

several times with vehicle stationary. This process ensures

nform
ercia

that brake pads are properly seated in their normal operating

position.
m

a
com

tion in
♦ Use the brake filling and bleeding equipment - VAS 5234- to
r
te o

thi
extract brake fluid from the brake fluid reservoir.

s
iva

do
r

♦ Fit brake pedal depressor - V.A.G 1869/2- before removing a

rp

cum
fo

brake caliper or disconnecting a brake hose. After that, open

en
ng

t.
yi
brake system to release pressure.
Co
Cop py
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o
by c lksw
cted agen
Prote AG.

68 Rep. gr.46 - Brakes - mechanism

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

1 - Rear axle shaft

❑ Removing and installing
⇒ Running gear, axles,
steering; Rep. gr. 42 ;
Repairing rear wheel
suspension (all-wheel
drive) .
2 - Axle beam with hub carrier
❑ Removing and installing
⇒ Final drive - differen‐
tial; Rep. gr. 39 ; Re‐
moving and installing
rear axle .
3 - Multi-point socket head bolt
❑ Renew each time after
removal ⇒ Running
gear, axles, steering;
Rep. gr. 42 ; Repairing agen
AG. Volkswagen AG d
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rear suspension (all- Volksw not
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wheel drive) . d b ara
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4 - Rear left speed sensor - aut ra
c
G46- for ABS ss

ce
le
un

❑ Before inserting sensor,

pt
an
d
itte

clean hole inner surface

y li
erm

ab
and coat with high-tem‐

ility
ot p

perature paste

wit
G 052 112 A3.
is n

h re
ole,

5 - Hexagon socket-head bolt

spec
urposes, in part or in wh

❑ Threaded connection

t to the co
for speed sensor
❑ Tightening torque 8 Nm

rrectne
6 - Cover plate
❑ Various versions ⇒
Running gear, axles, ss o
cial p

f
steering; Rep. gr. 42 ;
inform

Repairing rear wheel suspension (all-wheel drive)

mer

atio
m

7 - Torx bolt
o

n
c

i
or

❑ M6 x 12
thi
te

sd
a

❑ Threaded connection for splash plate

iv

o
pr

cum
r

❑ Tightening torque 10 Nm
fo

en
ng

t.
yi Co
8 - Wheel bearing/wheel bearing unit t. Cop py
rig
gh
❑ Removing and installing ⇒ Running gear, axles, steering; Rep. gr. 42 ; Repairing rear wheel suspension
ht
pyri by
Vo
(all-wheel drive) .
co lksw
by
cted agen
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9 - Bolt with washer
❑ Renew each time after removing
❑ Specified torque ⇒ Running gear, axles, steering; Rep. gr. 42 ; Repairing rear wheel suspension (all-
wheel drive)
10 - Brake disc
❑ When worn, renew on both sides of axle.
❑ Remove brake caliper and brake carrier prior to removing.
11 - Countersunk head bolt
❑ Threaded connection for brake disc
❑ Tightening torque 10 Nm

2. Rear brakes 69
 Caddy 2004 ➤ , Caddy 2011 ➤ en AG. Volkswagen AG
ag does
Brake systems - Edition 10.2018
Vol
ksw not
g y ua
db ran
rise tee
12 - Brake pads tho or
au ac
❑ Check thickness ; Booklet 39 . ⇒
s Maintenance
s

ce
e
nl
❑ Always renew on both sides of an axle.

pt
du

an
itte

y li
❑ Removing and installing ⇒ page 65
erm

ab
ility
ot p

13 - Backplate with different guide pins and protective caps

wit
, is n

❑ Supplied as a complete genuine part, pre-assembled with sufficient amount of grease on guide pins.

h re
hole

❑ If protective covers or guide pins are damaged, install repair kit and use lubricant sachet supplied to

spec
es, in part or in w

lubricate guide pins

t to the co
❑ Installation instructions ⇒ page 63
14 - Pad retainers

rrectness of i
❑ Always renew when changing pads.
l purpos

15 - Brake caliper
❑ Do not disconnect brake hose when changing pads.

nf
ercia

o
❑ Removing and installing ⇒ page 64

rm
m

atio
❑ Repairing ⇒ page 93
om

n in
c

❑ Adjust handbrake cable first after repairing or renewing.

or

thi
te

sd
a

❑ Adjusting handbrake, Caddy 2004 ▶ ⇒ page 81

iv

o
r
rp

cu
❑ Adjusting handbrake, Caddy 2011 ▶ ⇒ page 82
o

m
f

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ng

t.
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16 - Brake line t. Cop py
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❑ Tightening torque 14 Nm
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pyri by
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17 - Wire for rear left speed sensor - G46- for ABS cted agen
Prote AG.

18 - Handbrake cable
❑ Removing and installing ⇒ page 77
❑ Adjusting handbrake, Caddy 2004 ▶ ⇒ page 81
❑ Adjusting handbrake, Caddy 2011 ▶ ⇒ page 82
19 - Brake hose
❑ Removing and installing ⇒ page 115
20 - Brake hose retainer
21 - Hexagon bolt
❑ Self-locking
❑ Renew each time after removing
❑ Tightening torque 35 Nm
22 - Dual-combi bolt
❑ M12 x 1.5 x 50
❑ Threaded connection for brake carrier
❑ Renew each time after removing
❑ Torque setting 90 Nm and turn 90° further

70 Rep. gr.46 - Brakes - mechanism

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

2.9 Assembly overview - rear brakes, Bosch

BIR, Caddy 2011 ▶

Note

♦ Every time after changing pads, firmly depressVbrake

olkswa
pedal
several times with vehicle stationary. sThis
agenprocess ensures
AG. gen AG
does
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that brake pads are properly seatedy V in their normal operating
ol not
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position. edb ara
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♦ Use the brake filling andss ableeding
u
equipment - VAS 5234- to ra
c
extract brake fluid from the brake fluid reservoir.

ce
le
un

pt
♦ Fit brake pedal depressor - V.A.G 1869/2- before removing a

an
d
itte

y li
brake caliper or disconnecting a brake hose. After that, open
rm

ab
brake system to release pressure.
pe

ility
ot

wit
, is n

h re
hole

spec
1 - Dual-combi bolt
es, in part or in w

t to the co
❑ Renew each time after
removing
❑ Torque setting 90 Nm

rrectness of i
and turn 90° further
l purpos

2 - Hexagon socket-head bolt

❑ Threaded connection

nform
ercia

for speed sensor

❑ Tightening torque 8 Nm
m

a
com

tion in
3 - Rear left speed sensor -
r
te o

thi
G46- for ABS
s
iva

❑ Before inserting sensor, do

r
rp

cum

clean hole inner surface

fo

en
ng

and coat with high-tem‐

t.
yi Co
op
perature paste
C py
t. rig
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G 052 112 A3.
ht
pyri by
Vo
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by c lksw
4 - Axle assembly with stub
cted agen
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axle
❑ Various versions ⇒
Running gear, axles,
steering; Rep. gr. 42 ;
Repairing rear wheel
suspension (front-wheel
drive)
5 - Cover plate
❑ Various versions ⇒
Running gear, axles,
steering; Rep. gr. 42 ;
Repairing rear wheel
suspension (front-wheel
drive)
6 - Bolt
❑ Various versions ⇒
Running gear, axles,
steering; Rep. gr. 42 ;
Repairing rear wheel suspension (front-wheel drive)
7 - Wheel bearing/wheel bearing unit
❑ ⇒ Running gear, axles, steering; Rep. gr. 42 ; Repairing rear wheel suspension (front-wheel drive)
8 - Brake disc
❑ When worn, renew on both sides of axle.

2. Rear brakes 71
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018
❑ Remove brake caliper prior to removing.
9 - Torx bolt
❑ Threaded connection for brake disc
❑ Tightening torque 9 Nm
10 - Dust cap
❑ Renew each time after removal ⇒ Running gear, axles, steering; Rep. gr. 42 ; Repairing rear suspension
(front-wheel drive) .
11 - Bolt
❑ Renew each time after removal ⇒ Running gear, axles, steering; Rep. gr. 42 ; Repairing rear suspension
(front-wheel drive) .
12 - Brake pads
❑ Check thickness ⇒ Maintenance ; Booklet 39 .
❑ Always renew on both sides of an axle.
❑ Removing and installing ⇒ page 74
13 - Brake carrier with guide pins and protective cover
❑ Supplied as a complete genuine part, pre-assembled with sufficient amount of grease on guide pins.
❑ If protective covers or guide pins are damaged, install repair kit and use lubricant sachet supplied to
lubricate guide pins
14 - Brake caliper
❑ Do not disconnect brake hose when changing pads.
❑ Removing and installing ⇒ page 72
❑ Repairing ⇒ page 93
❑ Adjust handbrake cable first after repairing or renewing.
❑ Adjusting handbrake ⇒ page 82 .
15 - Hexagon bolt
❑ Self-locking
❑ Renew each time after removing
❑ Tightening torque 35 Nm agen
AG. Volkswagen AG d
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16 - Brake line d by V gu
ara
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❑ Tightening torque 14 Nm uthor eo
a ra
s c
17 - ABS speed sensor wire s
ce
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un

pt

18 - Handbrake cable
an
d
itte

y li

❑ Removing and installing ⇒ page 77

erm

ab
ility
ot p

❑ Adjusting handbrake ⇒ page 82 .

wit
is n

h re

19 - Spring clip
ole,

spec

❑ All-wheel drive vehicles only.

urposes, in part or in wh

t to the co

20 - Brake hose
❑ Removing and installing ⇒ page 115
rrectne

21 - Retaining clip
ss o
cial p

f i

2.10 Removing and installing brake caliper

nform
mer

atio

Special tools and workshop equipment required

om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
72
Prote AG.
Rep. gr.46 - Brakes - mechanism
 AG. Volkswagen AG Caddy 2004 ➤ , Caddy 2011 ➤
agen does
olksw Brake nosystems
t - Edition 10.2018
y V gua
db ran
rise tee
♦ Torque wrench - V.A.G 1331- autho or
ac
ss

ce
le
un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

♦ Brake pedal actuator - V.A.G 1869/2-

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

Removing

Note

The described procedure applies only to exchanging the brake

caliper or the following repair work on the brake caliper.

– Remove rear wheel.

– Press lever on brake caliper -4- backwards in direction of ar‐
row and unhook handbrake cable -1-.
Vehicles with all-wheel drive
– Remove retaining clips for handbrake cable.
Continuation for all vehicles
– Press locking lugs -2- together and pull handbrake cable out
of bracket on brake caliper.
– Release electrical connector of ABS speed sensor and pull it
off.
– Remove wire -3- from bracket of brake caliper.
– Connect bleeder bottle hose to brake caliper bleed valve and
open bleed valve.
– Insert brake pedal depressor - V.A.G 1869/2- into vehicle.
– Close bleeder screw and remove bleeder bottle.

2. Rear brakes 73
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Unbolt brake line.

– Unscrew both securing bolts from brake caliper, counter hold‐
ing on guide pin.
– Pull brake caliper from brake carrier.
AG. Volkswagen AG d
agen
Installing Volksw
oes
not
gu
by ara
d
• The piston is pressed back. orise nte
eo
th
u ra
• The brake pads are seated on the brake
ss a
carrier. c

ce
e
nl
– Secure brake caliper to brake carrier with new self-locking

pt
du

an
bolts. Tightening torque is 35 Nm.
itte

y li
erm

ab
– Fit brake line to brake caliper. Tightening torque is 14 Nm.

ility
ot p

wit
, is n

– Reconnect electrical connector of rear left speed sensor -

h re
G46- for ABS. Secure line in bracket on brake caliper.
hole

spec
es, in part or in w

– Clip handbrake cable into bracket on brake caliper. Attach

t to the co
handbrake cable to handbrake lever.
– Bleed brake system ⇒ page 99 .

rrectness of i
– Adjust handbrake ⇒ page 82 .
l purpos

– Fit rear wheel.

Specified torque of wheel bolts ⇒ Running gear, axles, steering;

nf
ercia

o
Rep. gr. 44 ; Fitting wheel .

rm
m

atio
om

n in
or c

Note

thi
te

sd
iva

o
r
rp

cu
♦ Every time after changing pads, firmly depress brake pedal
o

m
f

en
several times with vehicle stationary. This process ensures
ng

t.
yi Co
that brake pads are properly seated in their normal operating Cop py
position.
t. rig
gh ht
pyri by
Vo
co
♦ Check brake fluid level in brake fluid reservoir each time brake
by lksw
cted agen
Prote
pads are renewed.
AG.

2.11 Removing and installing brake pads/lin‐

ings
Special tools and workshop equipment required
♦ Torque wrench - V.A.G 1331-

74 Rep. gr.46 - Brakes - mechanism

 AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
orise Caddy
nte
eo
2004 ➤ , Caddy 2011 ➤
h
aut
Brake r a systems - Edition 10.2018
c
ss

ce
le
un
♦ Resetting and removal tool - T 10165-

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
Removing
mer

atio
om

n
c

Note

i
or

n thi
te

sd
iva

o
Mark reusable brake pads/linings when removing. Reinstall brake
pr

cum
r
fo

pads/linings in the same location to counteract an uneven brak‐

en
ng

t.
ing.
yi Co
Cop py
t. rig
gh ht
yri by
– Remove wheels. cop Vo
by lksw
cted agen
Prote
– Remove securing bolts from brake caliper, to do this counter‐
AG.

hold on guide pins.

– Remove brake caliper and secure it to body so that weight of
brake caliper does not strain or damage brake hose.
– Take brake pads out of brake carrier.
Cleaning the brake system

WARNING

Do not blow out brake system with compressed air. The re‐
sulting dust constitutes a health hazard!

– Thoroughly clean contact surfaces for brake pads on brake

carrier to remove brake dust and corrosion.
– Clean bonding surfaces of the brake caliper. They must be free
of adhesive material and grease.

Note

Clean brake caliper only with methylated spirits.

Installing

Note

Before pressing the brake piston back, draw off some brake fluid
from the reservoir. A brake fluid reservoir overflow may cause
damages when the brake piston is pressed back. For this pur‐
pose, use the brake filling and bleeding equipment - VAS 5234-
with the corresponding bleeder bottle.

2. Rear brakes 75
 n AG. Volkswagen AG do
lkswage es n
Caddy 2004 ➤d b, yCaddy
Vo 2011 ➤ ot g
ua
ran
Brake systems
horise
- Edition 10.2018 tee
ut or
a ac
ss
– Position resetting and removal tool - T 10165 - on brake caliper

ce
e
nl
as shown in illustration.

pt
du

an
itte

y li
– Screw in brake piston by turning wheel on piston compressing
erm

ab
and extracting tool - T 10165 - clockwise. Do not damage pro‐

ility
ot p

tective cover.

wit
, is n

h re
– To aid screwing in, use special tool T10165/1.
hole

spec
es, in part or in w

t to the co
Note

rrectness of i
If pistons are difficult to move, an open-end spanner »AF 13« can
be used on intended flats -arrow A-.
l purpos

– Pull protective foil off backing plates for brake pads.

nform
ercia

– Insert brake pads into brake carrier.

m

at
om

ion
– Place brake caliper in position.
c

in t
or

his
ate

do
priv

c
Note

um
for

en
ng

t.
yi Co
op
When positioning the brake caliper, ensure that the brake pads C py
t. rig
do not stick to the brake caliper before it is positioned correctly.
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote
– Secure brake caliper with new self-locking bolts. Tightening
AG.

torque is 35 Nm.
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Fitting wheel .

Note

♦ Every time after changing pads, firmly depress brake pedal

several times with vehicle stationary. This process ensures
that brake pads are properly seated in their normal operating
position.
♦ Check brake fluid level in brake fluid reservoir each time brake
pads are renewed.

76 Rep. gr.46 - Brakes - mechanism

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

3 Handbrake
⇒ “3.1 Assembly overview - handbrake lever”, page 77
⇒ “3.2 Removing and installing handbrake cable”, page 77
⇒ “3.3 Removing and installing handbrake cable, Caddy 2011 ▶”,
page 79
⇒ “3.4 Adjusting handbrake”, page 81
⇒ “3.5 Adjusting handbrake, Caddy 2011 ▶”, page 82

3.1 Assembly overview - handbrake lever

1 - Handbrake lever
❑ Before removing take AG. Volkswagen AG d
out centre console. agen oes
olksw not
V gu
by ara
2 - Nuts rised
nte
ho eo
❑ Qty. 4 aut ra
c
ss
❑ 15 Nm

ce
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nl

pt
du

an
3 - Handbrake lever trim
itte

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erm

ab
4 - Pull rod

ility
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wit
, is n

5 - Compensator

h re
hole

6 - Adjustment nut

spec
es, in part or in w

❑ Adjusting handbrake,

t to the co
Caddy 2004 ▶
⇒ page 81

rrectness of i
❑ Adjusting handbrake,
Caddy 2011 ▶
l purpos

⇒ page 82
7 - Handbrake cables

nf
ercia

o
❑ Removing and installing

rm
m

⇒ page 77

atio
om

n in
c

8 - Handbrake warning switch

or

thi
te

sd
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r
rp

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o

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f

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ng

t.
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Cop py
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o
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cted agen
Prote AG.

3.2 Removing and installing handbrake ca‐

ble
Removing
– Release handbrake.
Vehicles with drinks holder
– Remove drinks holder ⇒ General body repairs, interior; Rep.
gr. 68 ; Compartments, covers and trims .

3. Handbrake 77
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

Vehicles with no drinks holder

– Unclip cover from centre console (if fitted).

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

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pt
an
d
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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

Loosen adjustment nut -1- through the opening.

Continuation for all vehicles

Note

The centre console is not shown to improve clarity.

78 Rep. gr.46 - Brakes - mechanism

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Release adjustment nut -1- until relevant handbrake cable

-2- can be detached from compensator -3-.

– Press lever on brake caliper -1- forwards and unhook hand‐en AG. Volkswagen AG
brake cable. olks
wag does
not
V gu
by ara
– Detach handbrake cable by pressing the locking ed
oris lugs out of nte
the bracket on brake caliper. au
th eo
ra
ss c
– Remove retaining clip of speed sensor wire.

ce
e
nl

pt
du

an
– Pull handbrake cable out of guide pipe.
itte

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erm

ab
Installing

ility
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wit
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– Push handbrake cable into guide pipe and attach it to bracket.

h re
hole

spec
– Push handbrake cable into bracket on brake caliper until clip
es, in part or in w

engages.

t to the co
– Press lever on brake caliper forwards and attach handbrake
cable.

rrectness of i
– Secure speed sensor wire to handbrake cable.
l purpos

– Attach handbrake cable -2- to compensator -3-.

nform
ercia

– Pretension handbrake cable with adjustment nut -1-.

m

at
– Adjust handbrake ⇒ page 81 .
om

ion
c

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or

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ate

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for

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ng

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Cop py
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co lksw
by
cted agen
Prote AG.

3.3 Removing and installing handbrake ca‐

ble, Caddy 2011 ▶
Removing
– Release handbrake.
Vehicles with drinks holder
– Remove drinks holder ⇒ General body repairs, interior; Rep.
gr. 68 ; Compartments, covers and trims .

3. Handbrake 79
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

Vehicles with no drinks holder

– Unclip cover from centre console (if fitted).
Loosen adjustment nut -1- through the opening.
Continuation for all vehicles

Note

The centre console is not shown to improve clarity.

AG. Volkswagen AG d
agen oes
olksw not
V gu
by ara
– Release adjustment nut -1- until relevant
orised
handbrake cable nte
-2- can be detached from compensator
aut
h -3-. eo
ra
ss c

ce
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un

pt
an
d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
– Press lever on brake caliper -1- forwards and unhook hand‐ rrectness of i
l purpos

brake cable.
– Detach handbrake cable by pressing the locking lugs out of
nform
ercia

the bracket on brake caliper.

m

– Remove retaining clip of speed sensor wire.

a
com

tion in
r
te o

thi
s
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rp

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fo

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ng

t.
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Cop py
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by c lksw
– Unhook handbrake cable -3- from bracket -2-.
cted agen
Prote AG.

– Pull handbrake cable out of guide pipe.

Installing
– Push handbrake cable into guide pipe and attach it to bracket.
– Push handbrake cable into bracket on brake caliper until clip
engages.
– Press lever on brake caliper forwards and attach handbrake
cable.
– Secure speed sensor wire to handbrake cable.

80 Rep. gr.46 - Brakes - mechanism

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Attach handbrake cable -2- to compensator -3-.

– Pretension handbrake cable with adjustment nut -1-.
– Adjust handbrake ⇒ page 82 .
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

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rm

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pe

ility
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3.4 Adjusting handbrake

h re
hole

spec
A new adjustment is only necessary after renewing, handbrake
es, in part or in w

cables, brake calipers and brake discs.

t to the co
Vehicles with drinks holder

rrectness of i
– Remove drinks holder ⇒ General body repairs, interior; Rep.
gr. 68 ; Compartments, covers and trims .
l purpos

Vehicles with no drinks holder

nform
ercia

– Unclip cover from centre console (if fitted).

m

The adjustment nut is accessible without removing additional

a
com

tio
parts.

n in
r
te o

thi
Continuation for all vehicles
s
iva

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– Depress foot brake hard at least three times.
um
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– Pull handbrake on three times and then release again.
Co
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• Handbrake lever in rest position.
ht
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Prote AG.
Note

The centre console is not shown to improve clarity.

– Tighten adjusting nut -arrow (enlargement)- …

3. Handbrake 81
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– … until levers -1- on brake calipers lift off stops -2-.

– The total distance -a- to stops -2- on left and right brake cali‐
pers must not be below 1 mm or exceed 3 mm.
– Check that both wheels turn freely.
At the very least, adjustment nut must be screwed onto pull rod
so that one pull rod thread is visible. Otherwise the adjustment
nut does not self-lock.
Due to the automatic rear wheel brake adjustment there is no re‐
quirement to adjust the handbrake after making new/initial ad‐
justment.

3.5 Adjusting handbrake, Caddy 2011 ▶

A new adjustment is only necessary after renewing, handbrake
cables, brake calipers and brake discs.
Vehicles with drinks holder
– Remove drinks holder ⇒ General body repairs, interior; Rep.
gr. 68 ; Compartments, covers and trims .
Vehicles with no drinks holder
– Remove trim for rear centre console ⇒ General body repairs,
interior; Rep. gr. 68 ; Centre console; Removing and installing
trim for rear centre console .
Continuation for all vehicles
– Depress foot brake hard at least three times.
– Pull handbrake on three times and then release again.
• Handbrake lever in rest position.

Note
n AG. Volkswagen AG do
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The centre console is not shown toy Vimprove clarity.
lks es n
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– Tighten adjusting nut -arrow
auth (enlargement)- … or
ac
ss
– … until levers -1- on brake calipers lift off stops -2-.
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82
by lksw
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Rep. gr.46 - Brakes - mechanism Prote AG.
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– The total distance -a- to the stops -2- on left and right brake
calipers must not be below 4 mm or exceed 3 mm.
n AG. gen AG Volkswa
– Check that Vboth wage does
olks wheels turn freely. not
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At the very or
iseleast, adjustment nut must be screwedanonto
r
tee pull rod
so thatauthone pull rod thread is visible. Otherwise the adjustment
or
ac
nut does
ss not self-lock.

ce
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nl

pt
Due to the automatic rear wheel brake adjustment there is no re‐
du

an
itte

quirement to adjust the handbrake after making new/initial ad‐

y li
erm

ab
justment.

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es, in part or in w

t to the co
rrectness of i
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Prote AG.

3. Handbrake 83
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

4 Brake pedal
⇒ “4.1 Assembly overview - brake pedal”, page 84
⇒ “4.2 Separating brake pedal from brake servo”, page 85 agen
AG. Volkswagen AG d
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4.1 Assembly overview - brake pedal b gu
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WARNING s

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The brake pedal travel must not be restricted by additional floor

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coverings.
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h re
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Grease all mountings before installing with grease (part no.

spec
G 000 602).
es, in part or in w

t to the co
1 - Mounting bracket

rrectness of i
2 - Hexagon nut, self locking,
25 Nm
l purpos

3 - Brake light switch - F- and

brake pedal switch - F47-

nform
ercia

❑ On vehicles from model

m

a
year 2007, brake light
com

tion in
switch - F- is located on
r
te o

brake master cylinder

thi
s
iva

⇒ page 103 .

do
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cum
❑ Before installing brake
fo

en
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light switch, connect

n

t.
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op
brake pedal to brake C py
ht. rig
servo push rod rig ht
py by
⇒ page 85
co Vo
by lksw
cted agen
Prote
❑ Grease plunger head
AG.

with polycarbamide
grease G 052 142 A2.
❑ To ensure secure instal‐
lation, install brake light
switch only once.
❑ Adjusting brake light
switch ⇒ page 109 .
4 - Hexagon bolt
5 - Brake pedal
6 - Cap
7 - Bearing shell
8 - Support
❑ For ball head of brake
servo plunger rod.
9 - Hexagon nut, self locking,
25 Nm
10 - Bearing bush
11 - Pivot pin

84 Rep. gr.46 - Brakes - mechanism

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

4.2 Separating brake pedal agfrom

en AG. Vbrake ser‐
olkswagen AG
does
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or
Special tools and workshop aequipment
ut
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♦ Release tool - T10159-

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es, in part or in w

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rrectness of i
l purpos

– Pull connector off brake light switch.

nform
ercia

– Remove brake light switch by turning 45° towards left.

m

at
om

io
– First press brake pedal in direction of brake servo and hold.

n
c

in t
or

his
e

2 - Push bar
at

do
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3 - Retaining lugs

um
for

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t.
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– Insert release tool - T10159- and pull in direction of driver seat.
Co
op py
When doing this, counter-hold on brake pedal. (At this stage
. C rig
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the pedal must not be allowed to move backwards.) This action py by
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will press retaining lugs -3- of mounting off ball head of plunger
by lksw
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rod -2-.
AG.

For the sake of clarity, separation of brake pedal from brake servo
is shown with pedal cluster removed.
– Pull release tool - T10159- and brake pedal together towards
driver seat. (This action will pull the brake pedal off the ball
head of the plunger rod).
Installing

– Hold ball head of push rod in front of mounting and push brake
pedal in direction of brake servo, so that the ball head clicks
into place.
Further assembly is carried out in the reverse order.
– Adjust brake light switch ⇒ page 109 .

4. Brake pedal 85
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

47 – Brakes - hydraulics
1 Front brake caliper
⇒ “1.1 Assembly overview - brake caliper FS III”, page 86
⇒ “1.2 Removing and installing brake caliper FS III”, page 87
⇒ “1.3 Assembly overview - brake caliper FN3”, page 88
⇒ “1.4 Removing and installing brake caliper piston FN 3”,
page 89

1.1 Assembly overview - brake caliper FS III

♦ Install complete repair kit when servicing.
♦ Only use methylated spirits to clean brakes.
♦ Apply thin coat of assembly paste G 052 150 A2 to brake cyl‐
inders, pistons and seals.

1 - Dust cap
❑ Fit onto bleed valve
2 - Bleed valve, 10 Nm
❑ Apply thin coat of as‐ agen
AG. Volkswagen AG d
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sembly paste olksw not
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G 052 150 A2 to thread d by ara
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before screwing in. ut
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3 - Caps s

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pt
❑ Insert into mounting
an
d
itte

bush.
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pe

ility
4 - Guide pin, 30 Nm
ot

wit
, is n

5 - Bearing bush h re
hole

spec
❑ Insert into brake caliper.
es, in part or in w

t to the co

6 - Brake caliper
7 - Protective cap
rrectness of i

❑ Removing and installing

⇒ page 87
l purpos

❑ Do not damage when in‐

serting piston.
nform
ercia

8 - Piston
m

❑ Removing and installing

com

tion in

⇒ page 87
r
te o

thi

❑ Apply thin coat of as‐

s
iva

do

sembly paste
r
rp

cum

G 052 150 A2 to piston

fo

en
ng

before inserting.
t.
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Cop py
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9 - Sealing ring opyri
gh by
Vo
ht

❑ Removing and installing by c lksw

cted agen
⇒ page 87 Prote AG.

86 Rep. gr.47 - Brakes - hydraulics

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

1.2 Removing and installing brake caliper

FS III
Special tools and workshop equipment required
♦ Removal wedge - 3409-

♦ Piston resetting appliance - T 10145-

AG. Volkswagen AG d
agen oes
olksw not
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nl

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itte

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erm

ab
ility
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wit
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h re
hole

spec
es, in part or in w

Removing
t to the co

– Press piston out of brake caliper using compressed air.

Place a piece of wood in the recess to prevent damage to the
rrectness of i

piston.
l purpos

nform
mercia

at
om

ion
c

in t
or

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ate

do
priv

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for

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t.
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Cop py
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gh ht
yri by
– Remove seal using wedge 3409.cop Vo
by lksw
cted agen
Prote AG.
When removing ensure that the surface of the cylinder is not
damaged.
Installing
– The surfaces of the piston and seal must be cleaned only with
methylated spirits and then dried.
– Coat piston and seal thinly with assembly paste G 052 150 A2
before inserting.
– Insert seal in brake caliper.

1. Front brake caliper 87

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Place outer sealing lip of protective cap on the piston.

– Insert inner sealing lip into groove in cylinder using wedge
3409.

When doing this, hold piston in front of brake caliper.

– Press piston into brake caliper with piston resetting tool.

The outer sealing lip on the protective cap will then slip into the
piston groove.
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wit
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1.3 Assembly overview - brake caliper FN3

h re
hole

spec

♦ Install complete repair kit when servicing.

es, in part or in w

t to the co

♦ Only use methylated spirits to clean brakes.

♦ Apply thin coat of assembly paste G 052 150 A2 to brake cyl‐
rrectness of i

inders, pistons and seals.

l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

88 Rep. gr.47 - Brakes - hydraulics

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

1 - Dust cap
❑ Fit onto bleed valve
2 - Bleed valve, 10 Nm
❑ Apply thin coat of as‐
sembly paste
G 052 150 A2 to thread
before screwing in.
3 - Caps
❑ Insert into mounting
bush.
4 - Guide pin, 30 Nm
5 - Bearing bush
❑ Insert into brake caliper.
6 - Brake caliper
7 - Brake carrier
❑ Bolt onto brake caliper.
8 - Retaining spring
❑ Insert with both ends in
holes in brake caliper.
9 - Sealing ring
❑ Removing and installing
⇒ page 89
10 - Piston
❑ Removing and installing
⇒ page 89
❑ Apply thin coat of as‐
sembly paste
G 052 150 A2 to piston
before inserting.
11 - Protective cap wage
n AG. Volkswagen AG do
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lks
❑ Removingd band y V installing ⇒ page 89
o ot g
ua
e ran
❑ Do not thordamage when inserting piston.
is tee
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au ra
c
ss
ce
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nl

pt
du

1.4 Removing and installing brake caliper

an
itte

y li
erm

piston FN 3
ab
ility
ot p

wit
, is n

Special tools and workshop equipment required

h re
hole

♦ Removal wedge - 3409-

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

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ng

t.
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Cop py
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pyri by

89
co Vo
by lksw
cted 1. Front brake caliper
agen
Prote AG.
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

♦ Piston resetting appliance - T 10145-

♦ Assembly tool for protective cap - T10146/6-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
Removingss c
ce
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nl

pt

– Press piston out of brake caliper using compressed air.

du

an
itte

y li

Place a piece of wood in the recess to prevent damage to the

erm

ab
ility

piston.
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

– Lever off protective cap from brake caliper using wedge 3409.
at
om

ion
c

in t
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ate

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cum
for

en
ng

t.
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Cop py
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pyri by
Vo
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by c lksw
cted agen
Prote AG.

90 Rep. gr.47 - Brakes - hydraulics

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Remove seal using wedge 3409.

When removing ensure that the surface of the cylinder is not
damaged.
Installing
– The surfaces of the piston and seal must be cleaned only with
methylated spirits and then dried.
– Coat piston and seal thinly with assembly paste G 052 150 A2
before inserting.
– Insert seal in brake caliper.

– Fit protective seal -A- in assembly tool T10146/6 -1-.

– Press protective cap onto brake caliper so that it is fitted cor‐

rectly all round using assembly tool -1- and piston resetting
tool -2-.
Check seating of protective cap:

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
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nl

pt
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ab

– It should not be possible to remove protective cap from brake

ility
ot p

caliper by hand.
wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
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o

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f

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

1. Front brake caliper 91

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Press piston lightly onto protective seal and lock it in this po‐
sition with, for example, an assembly wedge -2-.

Note

Do not cant the piston to prevent damage to protective seal.

– Blow into protective cap using compressed air (max 3 bar)

-1-. The protective cap then springs onto piston.

– Press piston into brake caliper using piston resetting appliance

-1-.
The outer sealing lip on the protective cap will then slip into the
piston groove.

AG. Volkswagen AG d
agen oes
olksw not
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ris nte
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pe

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ot

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h re
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es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
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do
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cum
fo

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t.
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Cop py
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rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

92 Rep. gr.47 - Brakes - hydraulics

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

2 Rear brake caliper

⇒ “2.1 Assembly overview - brake caliper CI 38”, page 93
⇒ “2.2 Assembly overview - brake caliper CII 41”, page 94
⇒ “2.3 Assembly overview - brake caliper Bosch BIR”,
page 95 en AG. V
olkswagen AG
ag does
ksw not
Vol
⇒ “2.4 Dismantling and assembling brake caliper”, page 96 gu
by d ara
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⇒ “2.5 Pre-bleeding brake
ut
ho caliper”, page 98
r eo
a ra
ss c
2.1 Assembly overview - brake caliper CI 38

ce
e
nl

pt
du

an
♦ Install complete repair kit when servicing.
itte

y li
erm

ab
♦ Only use methylated spirits to clean brakes.

ility
ot p

wit
, is n

♦ New brake calipers are filled with brake fluid and are pre-bled.

h re
hole

spec
♦ Apply thin coat of assembly paste G 052 150 A2 to brake cyl‐
es, in part or in w

inders, pistons and seals.

t to the co
♦ When carrying out repairs it is essential to appropriately pre-
bleed the brake calipers (without brake pads) before installing

rrectness of i
in the vehicle ⇒ page 98 .
l purpos

1 - Brake caliper with hand‐

brake cable lever

nf
ercia

or
❑ If there is a leak at hand‐

m
m

atio
brake cable lever, re‐
om

new brake caliper.

n in
or c

thi
e

❑ Following repair work,

t

sd
iva

pre-bleed brake caliper

o
r
rp

cu

⇒ page 98 .
o

m
f

en
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t.
yi Co
2 - Dust cap t. Cop py
rig
gh ht
3 - Bleed valve, 10 Nm yri
p by
o Vo
by c lksw
❑ Apply thin coat of as‐ cted agen
Prote AG.
sembly paste
G 052 150 A2 to thread
before screwing in.
4 - Self-locking hexagon bolt,
35 Nm
❑ Renewing
❑ When loosening and
tightening, counter hold
on guide pin.
5 - Guide bolt
❑ Grease before fitting
protective cap.
6 - Protective cap
❑ Fit onto brake carrier
and guide pin.
7 - Brake carrier with guide
pins and protective cover
❑ Supplied as genuine
part, assembled with
sufficient grease on
guide pins.
❑ If protective caps or

2. Rear brake caliper 93

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

guide pins are dam‐

aged, install repair kit. Use lubricant sachet supplied to lubricate guide pins.
8 - Protective cap
❑ Pull on so that outer sealing lip goes over piston.
❑ Removing and installing ⇒ page 96
9 - Piston with automatic adjustment
❑ Removing and installing ⇒ page 96
❑ Apply thin coat of assembly paste G 052 150 A2 to piston before inserting.
10 - Sealing ring
❑ Removing and installing ⇒ page 96

2.2 Assembly overview - brake caliper sCIIagen

AG. Volkswagen AG d
oes
k w
41 ol not
byV gu
ara
ed nte
ris
♦ Install complete repair kit when servicing. autho eo
ra
ss c
♦ Only use methylated spirits to clean brakes.

ce
e
nl

pt
du

an
♦ New brake calipers are filled with brake fluid and are pre-bled.
itte

y li
erm

ab
♦ Apply thin coat of assembly paste G 052 150 A2 to brake cyl‐

ility
ot p

inders, pistons and seals.

wit
, is n

h re
♦ When carrying out repairs it is essential to appropriately pre-
hole

spec
bleed the brake calipers (without brake pads) before installing
es, in part or in w

in the vehicle ⇒ page 98 .

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

94 Rep. gr.47 - Brakes - hydraulics

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

1 - Brake caliper with hand‐

brake cable lever
❑ If there is a leak at hand‐
brake cable lever, re‐
new brake caliper.
❑ Following repair work,
pre-bleed brake caliper
⇒ page 98 .
2 - Dust cap
3 - Bleed valve, 10 Nm
❑ Apply thin coat of as‐
sembly paste
G 052 150 A2 to thread
before screwing in.
4 - Self-locking hexagon bolt,
35 Nm
❑ Renewing
❑ When loosening and
tightening, counter hold
on guide pin.
5 - Guide pins with steps
AG. Volkswagen AG d
❑ Shorter than item 6 ksw
agen oes
not
ol
❑ Grease before fitting byV gu
ara
ed
protective cap. horis nte
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aut ra
6 - Guide bolt ss c

ce
le

❑ Longer than item 5

un

pt
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d
itte

❑ Grease before fitting

y li
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ab
protective cap.
pe

ility
ot

wit
7 - Protective cap
, is n

h re
❑ Fit onto brake carrier
hole

spec
and guide pin.
es, in part or in w

t to the co
8 - Brake carrier with balance
weight
❑ Supplied as genuine part, assembled with sufficient grease on guide pins.
rrectness of i

❑ If protective caps or guide pins are damaged, install repair kit. Use lubricant sachet supplied to lubricate
l purpos

guide pins.
9 - Protective cap
nform
ercia

❑ Pull on so that outer sealing lip goes over piston.

m

a
com

❑ Removing and installing ⇒ page 96

ion in
r
te o

10 - Piston with automatic adjustment

thi
s
iva

do

❑ Removing and installing ⇒ page 96

r
rp

cum
fo

❑ Apply thin coat of assembly paste G 052 150 A2 to piston before inserting.
en
ng

t.
yi Co
op
11 - Sealing ring C py
ht. rig
rig ht
❑ Removing and installing ⇒ page 96 py by
co Vo
by lksw
cted agen
Prote AG.

2.3 Assembly overview - brake caliper

Bosch BIR
♦ Install complete repair kit when servicing.
♦ Only use methylated spirits to clean brakes.
♦ New brake calipers are filled with brake fluid and are pre-bled.

2. Rear brake caliper 95

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018 agen
AG. Volkswagen AG d
oes
olksw not
yV gu
♦ Apply thin coat of assembly paste G 052 150 A2 to brake rcyl‐
ised b ara
nte
inders, pistons and seals. ut
ho eo
ra
s a c
♦ When carrying out repairs it is essential to appropriately pre- s

ce
le
bleed the brake calipers (without brake pads) before installing

un

pt
an
d
in the vehicle ⇒ page 98 .

itte

y li
rm

ab
pe

ility
ot
1 - Brake caliper with hand‐

wit
, is n

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brake cable lever

hole

spec
❑ If there is a leak at hand‐

es, in part or in w
brake cable lever, re‐

t to the co
new brake caliper.
❑ Following repair work,
pre-bleed brake caliper

rrectness of i
⇒ page 98 . l purpos

2 - Dust cap
3 - Bleed valve, 10 Nm

nform
ercia

❑ Apply thin coat of as‐

m

a
com

t
sembly paste

ion in
G 052 150 A2 to thread
r
te o

thi
before screwing in.

s
iva

do
r
rp

c
4 - Self-locking hexagon bolt,

um
fo

35 Nm

en
ng

t.
yi Co
op
❑ Renewing C py
ht. rig
rig ht
❑ When loosening and py by
o Vo
tightening, counter hold
by c lksw
cted agen
on guide pin.
Prote AG.

5 - Guide bolt
❑ Grease before fitting
protective cap.
6 - Protective cap
❑ Fit onto brake carrier
and guide pin.
7 - Brake carrier with guide
pins and protective cover
❑ Supplied as genuine
part, assembled with
sufficient grease on
guide pins.
❑ If protective caps or
guide pins are dam‐
aged, install repair kit. Use lubricant sachet supplied to lubricate guide pins.
8 - Protective cap
❑ Pull on so that outer sealing lip goes over piston.
❑ Removing and installing ⇒ page 96
9 - Piston with automatic adjustment
❑ Removing and installing ⇒ page 96
❑ Apply thin coat of assembly paste G 052 150 A2 to piston before inserting.
10 - Sealing ring
❑ Removing and installing ⇒ page 96

2.4 Dismantling and assembling brake cali‐

per
Special tools and workshop equipment required

96 Rep. gr.47 - Brakes - hydraulics

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

♦ Resetting and removal tool - T 10165-

♦ Removal wedge - 3409-

Removing
– Screw piston out of brake caliper by turning thumb wheel anti-
clockwise.
Apply resetting and removal tool so that collar of tool is resting on
piston.
♦ If pistons are difficult to move, a 13 mm open-end spanner can
be used on intended flats -arrow A-.
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ility
ot

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– Remove seal using wedge 3409.

h re
hole

spec

Installing
es, in part or in w

t to the co

– The surfaces of the piston and seal must be cleaned only with
methylated spirits and then dried.
– Coat piston and seal thinly with assembly paste G 052 150 A2
rrectness of i

before inserting.
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
by
97
copy Vo
by lksw
cted agen 2. Rear brake caliper
Prote AG.
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Place protective cap with outer sealing lip on piston.

– Insert inner sealing lip into groove in cylinder using wedge
3409.

When doing this, hold piston in front of brake caliper.

– Screw in piston by turning thumb wheel clockwise.

. Volkswagen AG
gen AG does
swa
– To aid screwing in, use special tool T10165/1.yV
olk not
gu
d b ara
e
♦ Apply resetting and removal tool soththat
oris
collar of tool is resting nte
eo
on brake caliper. s au ra
c
s ce
e

♦ If the piston is pushed back using a piston resetting appliance

nl

pt
du

(e.g. T10145) or by depressing the brake pedal, the automatic

an
itte

y li
adjustment in the brake caliper will be destroyed.
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

2.5 Pre-bleeding brake caliper

rrectness of i

– Open bleeder valve -arrow A- and, using a commercially avail‐

l purpos

able bleeder bottle, fill with brake fluid until bubble-free brake
fluid flows from threaded hole of brake hose connection
nf
ercia

-arrow B-. Close bleeder valve.

orm
m

atio

Position brake caliper as illustrated to pre-bleed.

om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

98 Rep. gr.47 - Brakes - hydraulics

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

3 Hydraulic system
⇒ “3.1 General notes on brake fluid”, page 99
⇒ “3.2 Pre-bleeding hydraulic system”, page 99
⇒ “3.3 Bleeding hydraulic system following standard procedure”,
page 100
⇒ “3.4 Subsequent bleeding of hydraulic system”, page 101
⇒ “3.5 Testing for leaks”, page 102

3.1 General notes on brake fluid

WARNING

Only use new brake fluid conforming to VW standard

(VW 501 14).

Note

♦ Brake fluid is poisonous. Also due to its corrosive effect brake

fluid must not come into contact with paintwork.
gen AG
. Volkswagen AG
d a oes
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♦ Brake fluid is hygroscopic,
db
ywhich
Vo means it absorbs moisture
ot g
ua
from the ambient air and or
ise should therefore always be stored in
ran
tee
air-tight containers.auth or
ac
ss
♦ Wash away any spilt brake fluid using plenty of water.
ce
le
un

pt
an
d
itte

y li

Changing brake fluid

rm

ab
pe

ility

⇒ Maintenance ; Booklet ; Brake and clutch system: change

ot

wit
, is n

brake fluid.
h re
hole

spec

3.2 Pre-bleeding hydraulic system

es, in part or in w

t to the co

Special tools and workshop equipment required

♦ Brake filling and bleeding equipment - VAS 5234-
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Note Prote AG.

♦ Bleeding brake system on vehicles with ABS is performed in

same way as vehicles with a conventional brake system.
♦ Only use new brake fluid conforming to US standard
FMVSS 116 DOT 4 Hydraulan 404. Genuine VW/Audi brake
fluid conforms to this specification.

3. Hydraulic system 99
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

Pre-bleeding is necessary if a chamber of the brake fluid reservoir

ran completely empty (e.g. owing to leaks in brake system).
A pre-pressure of 2 bar is required for bleeding the hydraulic unit.
– Connect brake filling and bleeding equipment - VAS 5234- and
switch on.
1. Simultaneously bleed both front left and front right brake
caliper.

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agen oes
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ce
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un

pt
an
d
itte

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rm

ab
pe

ility
1. Simultaneously bleed both rear left and rear right brake cal‐
ot

wit
iper.
, is n

h re
hole

– Leave bleeder valves open with brake fluid hoses connected

spec
until brake fluid free from air bubbles flows out.
es, in part or in w

t to the co
– Then, bleed brake system normally ⇒ page 101 .

rrectness of i
l purpos

nform
mercia

a
com

tio
3.3 Bleeding hydraulic system following

n in
r
te o

thi
standard procedure
s
iva

do
r
rp

cum
fo

Special tools and workshop equipment required

en
ng

t.
yi Co
♦ Brake filling and bleeding equipment - VAS 5234- Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

100 Rep. gr.47 - Brakes - hydraulics

 AG. Volkswagen AG d
agen oes
olksw not
d byV Caddy
gu
ara 2004 ➤ , Caddy 2011 ➤
e
horis Brake nsystems
tee - Edition 10.2018
aut or
ac
ss
♦ Tool set for brake bleeding - VAS 6564-

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

Adhere strictly to work sequence when bleeding brake system.

nform
ercia

– Connect brake filling and bleeding equipment - VAS 5234- and

m

a
switch on.
com

tion in
r

A pre-pressure of 2 bar is required to bleed the hydraulic system.

te o

thi
s
iva

do
– Open bleeder valves in specified order and bleed brake cali‐
r
rp

cum
pers.
fo

en
ng

t.
yi Co
1. Front right brake caliper ht. Cop py
rig
rig ht
2. Front left brake caliper py by
co Vo
by lksw
cted agen
3. Rear right brake caliper Prote AG.

4. Rear left brake caliper

Note

Make sure to use a suitable bleeder hose. It must sit tightly on

bleeder valve so that no air can enter brake system.

– Leave bleeder valve of each brake caliper open with bleeder

hose fitted until brake fluid discharges free of air bubbles.

3.4 Subsequent bleeding of hydraulic sys‐

tem
If brake pedal is excessive or a so-called »spongy brake pedal«
is encountered, re-bleed system.
Subsequent bleeding requires the assistance of a second me‐
chanic.
Perform the following procedure:
– Connect brake filling and bleeding equipment - VAS 5234- .
– Depress brake pedal firmly and hold.
– Open bleeder valve on brake caliper.
– Fully depress brake pedal.
– Close bleed valve with pedal held down.
– Release brake pedal slowly.
This bleed sequence must be carried out 5 times per brake cali‐
per.
Bleeding sequence:
1 - Front left brake caliper
2 - Front right brake caliper

3. Hydraulic system 101

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

3 - Rear left brake caliper

4 - Rear right brake caliper
– After bleeding, perform road test. When doing this an ABS
regulation must be performed at least once.

3.5 Testing for leaks

Special tools and workshop equipment required
♦ Tester for brake pressure regulator - V.A.G 1310 A-

AG. Volkswagen AG d
agen oes
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ed
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nl

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itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
♦ Adapter M10 - V.A.G 1310/6-
es, in part or in w

t to the co
Test prerequisite
Brake system (hydraulic unit, brake hoses, brake lines and brake

rrectness of i
calipers) operating properly and free of leaks.
l purpos

Check
– Remove bleeder valve at one of front brake calipers.

nform
ercia

– Connect tester for brake pressure regulator - V.A.G 1310 A-

m

at
and bleed.
om

ion
c

in t
– Apply pressure to brake pedal until gauge indicates a pressure
or

his
e

of 50 bar.
at

do
priv

c
The pressure must not drop by more than 4 bar within the test

um
for

en
g

period of 45 seconds. Renew brake master cylinder if drop in

n

t.
yi Co
pressure exceeds specification. Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

102 Rep. gr.47 - Brakes - hydraulics

 AG. VolkswagenCaddy
AG do 2004 ➤ , Caddy 2011 ➤
agen
Volksw Brake esystems
s no
t gu - Edition 10.2018
d by ara
e nte
ris
ho eo
ut
4 Brake servo and brake master cylin‐ ss a ra
c

der

ce
le
un

pt
an
d
itte

y li
⇒ “4.1 Assembly overview - brake servo/brake master cylinder”,

erm

ab
page 103

ility
ot p

wit
is n
⇒ “4.2 Removing and installing brake master cylinder”,

h re
ole,
page 105

spec
urposes, in part or in wh
⇒ “4.3 Removing and installing brake servo”, page 107

t to the co
⇒ “4.4 Removing and installing brake light switch F and brake
pedal switch F47 to model year 2007”, page 109

rrectne
⇒ “4.5 Removing and installing brake light switch F from model
year 2007”, page 110

ss o
⇒ “4.6 Removing and installing brake light switch F , right-hand
cial p

f in
drive”, page 111

form
mer

atio
4.1 Assembly overview - brake servo/brake
om

n
c

master cylinder

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

Note

en
ng

t.
yi Co
Cop py
Use only new brake fluid. Observe information on brake fluid res‐
t. rig
gh ht
yri by
ervoir! op Vo
by c lksw
cted agen
Prote AG.

4. Brake servo and brake master cylinder 103

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018
AG. Volkswagen AG d
1 - Pedal cluster agen oes
olksw not
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by ara
2 - Hexagon nut,risself locking,
ed
nte
25 Nm aut
ho eo
ra
s c
❑ Renews each time after

ce
e

removing
nl

pt
du

an
itte

y li
3 - Seal
erm

ab
ility
❑ For brake servo.
ot p

wit
, is n

4 - Brake servo

h re
hole

spec
❑ On petrol engines, the
es, in part or in w

required vacuum is ob‐

t to the co
tained at the intake con‐
necting piece.
❑ Diesel engines are fitted

rrectness of i
with a vacuum pump to
l purpos

generate the necessary

vacuum pressure
⇒ page 114 .

nform
ercia

❑ Operation check:
m

at
om

– With engine switched

ion
c

off, depress brake pedal

in t
or

his
e

firmly several times (to

at

do
riv

exhaust any negative

p

cum

pressure in the unit).

for

en
ng

t.
yi Co
op
– Now depress brake C py
t. rig
pedal with average foot
gh ht
yri by
pressure, hold and start
op Vo
by c lksw
cted
engine. If the servo unit
agen
Prote AG.
is working properly, the
brake pedal will now
give perceptibly under
foot (servo assistance
becomes activated).
❑ If faulty, renew com‐
plete.
❑ Removing and installing ⇒ page 107
5 - Sealing ring
6 - Tandem brake master cylinder with no brake light switch
❑ For allocation, refer to ⇒ Electronic parts catalogue (ETKA) .
❑ Cannot be repaired. If faulty, renew complete.
❑ Removing and installing ⇒ page 105
7 - Heat shield
For allocation, refer to ⇒ Electronic parts catalogue (ETKA) .

8 - Hexagon nut, self locking, 25 Nm

❑ Renew each time after removing
9 - Torx socket head bolt, 5 Nm
10 - Brake light switch - F-
❑ Including brake pedal switch - F47- .
❑ In vehicles before model year 2007, brake light switch - F- is located on brake pedal ⇒ page 109 .
❑ Removing and installing ⇒ page 110
11 - Tandem brake master cylinder with brake light switch
❑ For allocation, refer to ⇒ Electronic parts catalogue (ETKA) .
❑ Cannot be repaired. If faulty, renew complete.
❑ Removing and installing ⇒ page 105

104 Rep. gr.47 - Brakes - hydraulics

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

12 - Brake line, 14 Nm
n AG. Volkswagen AG do
❑ Brake master cylinder/secondary piston circuitVoto wage
lkshydraulic unit es n
ot g
y ua
db ran
13 - Brake line, 14 Nm ris
e
tee
tho or
❑ Brake master cylinder/primary piston
ss
aucircuit to hydraulic unit ac

ce
le
14 - Sealing cover

un

pt
an
d
itte

y li
15 - Brake fluid reservoir

erm

ab
ility
ot p
16 - Vacuum hose

wit
is n
❑ Fit in brake servo.

h re
ole,

spec
17 - Sealing plug
urposes, in part or in wh

t to the co
❑ Connection for vacuum hose.
18 - Sealing plug

rrectne
❑ Moisten with brake fluid and press into brake fluid reservoir.

ss o
cial p

4.2 Removing and installing brake master

f inform
cylinder
mer

atio
om

Special tools and workshop equipment required

n
c

i
or

n thi
e

♦ Brake filling and bleeding equipment - VAS 5234-

t

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

♦ Torque wrench - V.A.G 1331-

Removing
– Note or request radio code on vehicles with coded radio if
necessary.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and reconnecting battery .
Vehicles with diesel engine:
– Remove air filter housing together with intake hose ⇒ Rep.
gr. 23 .

4. Brake servo and brake master cylinder 105

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

Continued for all vehicles:

– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing battery .
– Remove battery tray.
– Lay out sufficient lint free clothes in area of engine and gear‐
box.
– Extract as much brake fluid as possible from brake fluid res‐
ervoir using brake filling and bleeding equipment - VAS 5234- .
– Disconnect connector -A- from brake fluid level warning con‐
tact.
Vehicles with manual gearbox:
– Detach supply hose -B- for clutch master cylinder and seal.
Vehicles from model year 2007:

– Separate connector -1- from brake light switch - F- .

Continued for all vehicles:
– Remove brake fluid reservoir. To do this press locking tabs on
reservoir outwards and simultaneously pull brake fluid reser‐
voir out of sealing plugs.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
ss c ce
le

– Unscrew brake lines -1- from brake master cylinder and seal
un

pt

brake lines with plugs from repair kit Part No. 1H0 698 311 A.
an
d
itte

y li
rm

ab

– Remove nuts -2- from brake master cylinder.

pe

ility
ot

wit

– Remove heat shield (if installed).

, is n

h re
hole

– Carefully take brake master cylinder out of brake servo.

spec
es, in part or in w

Installing
t to the co

– Installation is carried out in reverse order.

rrectness of i

Observe the following important points when installing:

l purpos

– When assembling brake master cylinder with brake servo,

make sure plunger rod is properly positioned in brake master
cylinder.
nform
ercia

– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐

m

necting and reconnecting battery .

com

tion in
r

– Bleed brake system ⇒ page 99 .

te o

thi
s
iva

do

Tightening torques:
r
rp

cum
fo

en
g

Brake master cylinder to brake servo 25 Nm

n

t.
yi Co
♦ Use new nuts! ht. Cop py
rig
rig ht
py by
Brake lines to brake master cylinder 14 Nm co Vo
by lksw
cted agen
Prote AG.

106 Rep. gr.47 - Brakes - hydraulics

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

4.3 Removing and installing brake servo

Special tools and workshop equipment required
♦ Brake filling and bleeding equipment - VAS 5234-

♦ Torque wrench - V.A.G 1331-

AG. Volkswagen AG d
agen oes
Removing olksw not
V gu
d by ara
e
– Note or request radio code on vehicles with codedthoradio if
ris nte
eo
necessary. s au ra
c
s

ce
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
e
nl

pt
du

necting and reconnecting battery .

an
itte

y li
erm

ab
Vehicles with diesel engine:

ility
ot p

wit
– Remove air filter housing together with intake hose ⇒ Rep.
, is n

h re
gr. 23 .
hole

spec
Continued for all vehicles:
es, in part or in w

t to the co
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Removing
and installing battery .
rrectness of i

– Remove battery tray.

l purpos

– Unclip cable guide -1- from longitudinal member.

– Remove charge air pipe together with connecting hoses be‐
nform
ercia

tween charge air cooler and turbocharger ⇒ Rep. gr. 21 .

m

at

Continued for all vehicles:

om

ion
c

in t
r

– Lay out sufficient lint free clothes in area of engine and gear‐
o

his
e

box.
at

do
priv

cum
or

– Extract as much brake fluid as possible from brake fluid res‐

f

en
g

ervoir using brake filling and bleeding equipment - VAS 5234- .

n

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

4. Brake servo and brake master cylinder 107

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Disconnect connector -A- from brake fluid level warning con‐

tact.
AG. Volkswagen AG d
Vehicles with manual gearbox: agen oes
olksw not
V gu
by ara
– Detach supply hose -B- for clutch
rised master cylinder and seal. nte
ho eo
ut
Vehicles from model year 2007:
ss a ra
c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

– Separate connector -1- from brake light switch - F- .

t to the co
Continued for all vehicles:

rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

– Remove brake fluid reservoir. To do this press locking tabs on

en
ng

t.
reservoir outwards and simultaneously pull brake fluid reser‐
yi Co
op py
voir out of sealing plugs. t. C rig
gh ht
pyri by
– Unscrew brake lines -1- from brake master cylinder and seal
o Vo
by c lksw
cted
brake lines with plugs from repair kit Part No. 1H0 698 311 A.
agen
Prote AG.

– Remove nuts -2- from brake master cylinder.

– Remove heat shield (if installed).
– Carefully take brake master cylinder out of brake servo.
– Pull vacuum hose off brake servo and tandem pump.
Vehicles up to model year 2007:

– Pull connector -1- off brake light switch - F- .

Removal and installation of the brake light switch may only be
carried out while operating rod is pressed in, otherwise the locking
element of the brake light switch will be damaged.
– Remove brake light switch -2- by turning 45° towards left.
Continued for all vehicles:
– Remove cover -4-.
– Separate brake pedal from brake servo ⇒ page 85 .

108 Rep. gr.47 - Brakes - hydraulics

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Unscrew nuts -1- from brake servo.

– Remove both upper nuts -2- from mounting bracket.
– Carefully remove brake servo from vehicle.
AG. Volkswagen AG d
Installing agen oes
olksw not
V gu
by ara
– Installation risisedcarried out in reverse order. nte
ho eo
ut
Observe following
ss a points when installing: ra
c

ce
e

Vehicles up to model year 2007:

nl

pt
du

an
itte

y li
– Install brake light switch ⇒ page 109 .
erm

ab
ility
ot p

Continued for all vehicles:

wit
, is n

h re
– Clip brake pedal to brake servo ⇒ page 85 .
hole

spec
– Connect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
es, in part or in w

necting and reconnecting battery .

t to the co
– Bleed brake system ⇒ page 99 .

rrectness of i
Tightening torques:
l purpos

Brake servo to pedal cluster and plenum chamber 25 Nm

bulkhead
♦ Use new nuts!

nform
ercia

Brake master cylinder to brake servo 25 Nm

m

at
om

i
♦ Use new nuts!
on
c

in t
or

his
e

Brake lines to brake master cylinder 14 Nm

at

do
priv

cum
for

en
g

4.4 Removing and installing brake light

n

t.
yi Co
op py
switch - F- and brake pedal switch - F47-
t. C rig
gh ht
yri by
to model year 2007
op Vo
by c lksw
cted agen
Prote AG.
In vehicles from model year 2007, the brake light switch is located
on the brake master cylinder ⇒ page 103 .

4. Brake servo and brake master cylinder 109

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
Note utho
or
a ac
ss
♦ Old-version brake light switches must be renewed every time

ce
le
un

pt
they are removed. Only new-version brake light switches are

an
d
itte
offered as spare part.

y li
rm

ab
pe

ility
♦ The most noticeable difference to the old-version brake light

ot

wit
switch is the bright tip of the plunger head -A-.

, is n

h re
hole

spec
Removing

es, in part or in w

t to the co
– Pull connector off brake light switch.
Removal and installation of the brake light switch may only be

rrectness of i
carried out while operating rod is pressed in, otherwise the locking
element of the brake light switch will be damaged.
l purpos

– Remove brake light switch by turning 45° towards left.

nform
ercia

Installing, adjusting and locking

m

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com

tion in
Note
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Old-version brake light switches must be renewed every time they
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Before assembling the brake light switch, grease the bright tip of
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the plunger head with polycarbamide grease G 052 142 A2. p by
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• The brake pedal must remain at rest position while the brake Prote AG.

light switch is being installed. The brake pedal must not be

touched by anything but the plunger head throughout the en‐
tire installation.

– Guide brake light switch through fitting hole -arrow 1- and

press it against pedal with head of plunger. Then turn brake
light switch 45° to right -arrow 2- until it can be felt to engage.
– Fit brake light switch connector.
– Check function of brake light.

4.5 Removing and installing brake light

switch - F- from model year 2007

Note

In vehicles prior to model year 2007, the brake light switch is lo‐
cated on the brake pedal. ⇒ page 84

Removing
– Remove air filter. ⇒ Rep. gr. 23

110 Rep. gr.47 - Brakes - hydraulics

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Separate connector -1- from brake light switch - F- .

– Remove bolt -2- from brake master cylinder.
– Pull brake light switch - F- -3- from brake master cylinder at
bottom and remove from locking lug at top -4-.
Installing
– Installation is carried out in reverse order.
Specified torques:
Torx bolt to brake master cylinder 5 Nm

4.6 Removing and installing brake light

switch - F- , right-hand drive
Removing
Vehicles with diesel engine
– If fitted, remove heat shield -1- from diesel particulate filter by
unscrewing nuts -arrows-.

– Remove upper timing belt guard by detaching clips -arrows-.

AG. Volkswagen AG d
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es, in part or in w

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111
agen
Prote AG.
4. Brake servo and brake master cylinder
 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Release electrical connector -2- from exhaust gas pressure

sensor 1 - G450- and pull off.
– Remove bolt -4-.
– Remove screw -3-.
– Remove exhaust gas pressure sensor 1 - G450- and place
aside.
– Remove securing bolts -1- and take out bracket.

– Unclip heat shield and place to one side.

Continued for all vehicles

AG. Volkswagen AG d
agen oes
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– Remove heat shield -3- (if fitted) by unscrewing nuts -4-.

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
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– Separate connector -A- from brake light switch - F- and pull

te

sd
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off.
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The brake light switch - F- must then be removed from below.
o
by c lksw
cted agen
Prote AG.

112 Rep. gr.47 - Brakes - hydraulics

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Remove bolt -1- from brake master cylinder.

– Pull brake light switch - F- -2- off the brake master cylinder
underneath and out of the clip at the top -arrow-.
Installing
Installation is carried out in reverse order. During this step, ob‐
serve the following:
– Insert brake light switch - F- properly in guide.

Torque setting
Component Torque setting
Brake light switch - F- to brake master cylinder 5 Nm

AG. Volkswagen AG d
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Prote AG.

4. Brake servo and brake master cylinder 113

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

5 Vacuum system
⇒ “5.1 Vacuum pump for brake servo (vehicles with diesel en‐
gine)”, page 114
⇒ “5.2 Checking non-return valve ”, page 114

5.1 Vacuum pump for brake servo (vehicles

with diesel engine)
Vacuum pump for 4-cylinder diesel engine (2-valve):
Tandem pump -1- (vacuum pump and fuel pump)
Vacuum hose to brake servo -2- with non-return valve.
Fuel lines -3 and 4-.
– Removing and installing tandem pump ⇒ Rep. gr. 15 ; Cyl‐
inder head, valve gear; Removing and installing vacuum
pump .

Vacuum pump for 4-cylinder diesel engine (4-valve):

n AG. Volkswagen AG age does
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Tandem pump -4- (vacuum
by
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Vacuum hose tothobrake
r
servo -1- with non-return valve. eo
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Fuel lines -2sand 3-.
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nl

pt
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– Removing and installing tandem pump ⇒ Rep. gr. 15 ; Cyl‐

an
itte

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inder head, valve gear; Removing and installing vacuum

erm

ab

pump .
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5.2 Checking non-return valve

rrectness of i

♦ Air must pass through non-return valve -A- in direction of ar‐

row.
l purpos

♦ Non-return valve must remain closed in opposite direction.

nform
ercia

Observe correct installation position!

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114 Rep. gr.47 - Brakes - hydraulics

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

6 Brake lines/brake hoses

⇒ “6.1 Removing and installing front brake hoses”, page 115
AG. Volkswagen
⇒ “6.2 Removing and installing rear brake
lksw
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n
page 116
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⇒ “6.3 Repairing brake lines”,rispage
ed 117 ran
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⇒ “6.4 Assembly overview au- flanging tool”, page 118 ac
ss

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⇒ “6.5 Work instructions”, page 119
nl

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6.1 Removing and installing front brake ho‐

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erm

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ses
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hole

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Note
es, in part or in w

t to the co
Make sure that brake hoses are installed without twisting and
check for clearance when installing.

rrectness of i
Special tools and workshop equipment required
l purpos

♦ Brake pedal actuator - V.A.G 1869/2-

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mercia

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Removing

Note

The illustrations are a symbolic representation and do not nec‐

essarily match the actual vehicle.

– Remove wheels.
– Connect bleeder bottle hose to brake caliper bleed valve and
open bleed valve.
– Apply brake pedal depressor - V.A.G 1869/2- .
– Close bleed valve and remove bleed bottle.

6. Brake lines/brake hoses 115

 . Volkswagen AG
gen AG does
swa
Caddy 2004 ➤ , Caddy 2011 y V➤
olk not
gu
b ara
Brake systems - Editionris10.2018
ed
nte
ho eo
aut ra
– Release bolt -arrow- from
s brake caliper.
s c

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le
un

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an
d
itte

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spec
urposes, in part or in wh

t to the co
rrectness
– Release brake line -2- -arrow- and pull brake hose -1- away

o
cial p

f
downwards.

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mer

atio
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Prote AG.

– Pull off clip -1- and remove brake hose -2- from brackets
-direction of arrow-.
Installing
– Install brake hose in reverse order; secure in position with clip
to prevent twisting.
– Remove brake pedal depressor - V.A.G 1869/2- .
– Bleed brake system ⇒ page 99 .
– Fit wheels.
Tightening torques:
Brake lines to brake hose 14 Nm
Brake hose to brake caliper 35 Nm

6.2 Removing and installing rear brake ho‐

ses

Note

The illustrations are a symbolic representation and do not nec‐

essarily match the actual vehicle.

Removing
– Connect bleeder bottle hose to brake caliper bleed valve and
open bleed valve.
– Apply brake pedal depressor - V.A.G 1869/2- .

116 Rep. gr.47 - Brakes - hydraulics

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Close bleed valve and remove bleed bottle.

– Detach brake hose -1- from bracket -2-.

– Release brake line -1-.

– Pull off clips -2-.
– Pull brake hose out -3-.
Installing
– Install brake hose in reverse order; secure in position with clip
to prevent twisting.
– Remove brake pedal depressor - V.A.G 1869/2- .
– Bleed brake system ⇒ page 99 . AG. Volkswagen AG d
agen oes
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Tightening torques: d by
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6.3 Repairing brake lines

hole

spec
es, in part or in w

The flanging tool for brake lines - VAS 6056- can be used to flange
t to the co

brake lines with an outer pipe diameter of 5 mm without damaging

the coating. In certain cases, this enables partial brake line sec‐
tions to be renewed at less expense.
rrectness of i

The use of flanging tool V.A.G. 1356 is not permitted due to the
l purpos

coating and the diameter of the black brake lines.

nform
ercia

Note
m

at
om

ion
c

♦ Brake pipes may only be bent up to max. 90°. They otherwise

in t
or

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kink or reveal deformations which constrict the pipe cross-

at

do
riv

section unacceptably.
p

cum
for

♦ Preferably separate brake lines at underbody.

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♦ The positions of the intermediate pieces must be selected so t. C rig
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that they cannot chafe on moving parts. pyri by
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♦ Do not grease spindle; merely clean with methylated spirits.
agen
Prote AG.

6. Brake lines/brake hoses 117

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

Special tools and workshop equipment required

♦ Flanging tool for brake lines - VAS 6056-

AG. Volkswagen A
♦ Brake filling and bleeding oequipment
lksw
agen - VAS 5234-
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List of individual tools:

rrectness of i

Item Tool Tool number

l purpos

1 Flanging tool (including flanging VAS 6056/1

jaws VAS 6056/6)
nf
ercia

or

2 Pipe cutter VAS 6056/2

m
m

atio
m

3 Brake line scraper1) VAS 6056/3

o

n in
or c

4 Set of grips with plastic jaws VAS 6056/4

thi
te

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5 Pipe bending tool VAS 6056/5

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6 Special wrench, 6 mm -
f

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7 Flanging jaws VAS 6056/7
C py
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1) Grub screws (in shaft and at side) are adjusted and must not be tampered co Vo
by lksw
with! Prote
cted AG.
agen

6.4 Assembly overview - flanging tool

118 Rep. gr.47 - Brakes - hydraulics

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018
AG. Volkswagen AG d
1 - Flanging tool upper part agen oes
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❑ Unbolt to change flang‐ ed b ara
nte
is
ing jaws. hor eo
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2 - Fastening for handle ss

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❑ Must be unbolted to ac‐

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cess securing bolt for

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upper part

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3 - Securing bolt

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❑ For flanging tool upper hole

spec
part
es, in part or in w

t to the co
4 - Grub screws for flanging
jaws
❑ For centring and holding

rrectness of i
flanging jaws
l purpos

❑ Allen head bolt, 2 mm

5 - Flanging jaws

nform
ercia

❑ Various.
m

at
❑ Assembly instructions
om

ion
⇒ page 119 .
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Flanging jaw assembly instructions:

♦ VAS 6056/6 (dark) for black brake lines
♦ VAS 6056/7 (light) for green brake lines

Note

Arrow on rounded side of flanging jaws must point to edge of

housing. Straight side of flanging jaws must be installed to spin‐
dle, as flanging head is not otherwise formed correctly.

6.5 Work instructions

– Unbolt relevant brake line at brake caliper or wheel brake cyl‐
inder; catch escaping brake fluid and dispose of this as per
regulations.

6. Brake lines/brake hoses 119

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Cut through brake line at a suitable point (straight, freely ac‐

cessible section) with pipe cutter -2-.
– Remove section to be renewed.
AG. Volkswagen AG d
agen oes
– Degrease brake line surface. olksw not
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ility
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– Clamp brake line in grip wrench -4- so that approx. 50 mm

spec
project out of plastic jaws.
es, in part or in w

t to the co
– Clamp scraper -3- in a drill and position on brake line.
– At slow drill speed and with gentle pressure on brake line,

rrectness of i
scrape coating off brake line.
l purpos

Length of scraping is determined by stop in scraper.

– Remove scraper from brake line and remove scraping resi‐

nf
ercia

dues.

orm
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– Remove set of grips and slide pipe bolt -D- onto brake line.
o
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Prote AG.

– Slide brake line -B- to stop -A- in flanging tool.

Note

Brake line must be positioned against stop when the hexagon

socket head bolts are tightened, or the flange will not be formed
correctly.

120 Rep. gr.47 - Brakes - hydraulics

 Caddy 2004 ➤ , Caddy 2011 ➤
Brake systems - Edition 10.2018

– Pre-tension brake line in flanging tool until brake line can no

longer be moved. Then fold up stop -A- and use angled driver
-C- to tighten hexagon socket head bolts in diagonal se‐
quence.

– Turn spindle to stop in flanging tool.

– Turn spindle back again.
– Undo Allen head bolts alternately in diagonal sequence.
– Remove brake line from flanging tool. Clean and check brake
line and flange.
Briefly flush the section of brake line remaining in the vehicle:
– Connect brake filling and bleeding equipment - VAS 5234- ,
connect bleeder bottle hose to brake line flange and allow
brake filling and bleeding equipment - VAS 5234- to run briefly
until a little brake fluid has run through.
– Blow out new brake line to be inserted
gen AG
with
. Volkswagencompressed
AG d air.
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– Join brake lines rusing
ise
d connector -E-. ara
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– Install brakes aline.
u ra
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s
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e

– Bleed brake system ⇒ page 99 .

nl

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itte

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erm

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ility
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es, in part or in w

t to the co
rrectness of i
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nf
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Prote AG.

6. Brake lines/brake hoses 121