Service

Workshop Manual
Citigo 2012 ➤
Brake systems
Edition 11.2012

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

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

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
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 © 2015 ŠKODA AUTO a. s. D3E80488B21

 Citigo 2012 ➤
Brake systems - Edition 11.2012

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Brake variants and their assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Brake inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Checking vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1 Antilock braking system (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 General instructions for ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Repair instructions for repair work on ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Vehicle Diagnosis, Measurement and Information System . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Indication of faults by means of warning lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Fitting location overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1 ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 ABS/ESC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 Removing and installing control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Connecting brake lines to hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1 Assembly overview - speed sensor on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 Removing and installing wheel speed sensor on the front axle . . . . . . . . . . . . . . . . . . . . . . 21
4.3 Assembly overview - speed sensor on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4 Removing and installing wheel speed sensor on the rear axle . . . . . . . . . . . . . . . . . . . . . . 23
4.5 Removing and installing steering angle sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.6 Removing and installing yaw rate sender and lateral acceleration sender . . . . . . . . . . . . 23

46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1 Repairing front wheel brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.1 Changing the brake pads of the front brake - Mounting instructions . . . . . . . . . . . . . . . . . . 24
1.2 Assembly overview - front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.3 Removing and installing brake pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.4 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2 Repairing rear brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.1 Replacing the brake shoes of the rear brake - Mounting instructions . . . . . . . . . . . . . . . . 30
2.2 Assembly overview - rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3 Resetting drum brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.4 Removing and installing brake shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3 Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.1 Handbrake - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.2 Removing and installing the rear handbrake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.3 Setting the hand-brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.1 Summary of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Protected by 4.2 Separating
copyright. Copying for privatethe brake pedal
or commercial purposes,from
in part the brake
or in whole, servo
is not unit . . . . . . . . . . . . . . . . . . . . . . . . . . . .
permitted 43
4.3
unless authorised Clipping
by ŠKODA AUTO A.the brake
S. ŠKODA AUTOpedal onto
A. S. does notthe brake
guarantee servo
or accept anyunit
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.4 Removing and installing brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.5 Removing and installing the foot controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1 Front brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Contents i
 Citigo 2012 ➤
Brake systems - Edition 11.2012

1.1 Assembly overview - front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

1.2 Removing and installing brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2 Brake Servo Unit/Master Brake Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.1 Assembly overview - brake servo/brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.2 Removing and installing brake light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.3 Removing and installing master brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.4 Removing and installing brake servo unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3 Vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.1 Checking the non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.2 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4 Brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.1 Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
5 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.1 General notes on brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
5.2 Bleeding the brake system of air with the brake filling and bleeding device . . . . . . . . . . . . 72
5.3 Bleeding the brake system of air without using the brake filling and bleeding device . . . . 73
5.4 Checking the master brake cylinder for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
5.5 Testing wheel-brake cylinder for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

ii Contents
 Citigo 2012 ➤
Brake systems - Edition 11.2012

00 – Technical data
1 Brakes
(SRL000549; Edition 11.2012)
Brake variants and their assignment ⇒ page 1 .

1.1 Brake variants and their assignment

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Brakes 1
 Citigo 2012 ➤
Brake systems - Edition 11.2012

Engine 1.0 ltr./44 kW 1.0 ltr./55 kW

Engine code letters: CHYA CHYB
Master brake cylinder - ∅ mm 20,64
Brake servo unit - ∅ Inch 9 - Left-hand drive vehicles
8.5 - right-hand drive vehicles
♦ Front disc brake:

Front brake caliper (type denomination) FS III (14”) FS III (14”)

Front brake caliper, piston - ∅ mm 54 54
Front brake disc - ∅ mm 256 256
Brake disc, thickness mm 22 22
Brake disc, minimum thick‐ mm 19 19
ness
Pad thickness with supporting mm 19,6 19,6
plate
Minimum pad thickness with‐ mm 2 2
out supporting plate
♦ Rear drum brake:

Brake drum - ∅ mm 200 200

Brake drum - maximum diam‐ mm 201,5 201,5
eter ∅
Wheel-brake cylinder - ∅ mm 17,64 17,64
Brake pad, width mm 40 40
Pad thickness without sup‐ mm 5 5
porting shoe
Minimum pad thickness with‐ mm 2,5 2,5
out supporting shoe

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
2
 Citigo 2012 ➤
Brake systems - Edition 11.2012

2 Brake inspection
General Instructions ⇒ page 3 .
Checking vehicles with front-wheel drive ⇒ page 3 .

2.1 General Instructions

♦ The drive is provided by the test rig.
♦ During the testing, the idling speed must be set on vehicles
with manual gearbox and the driving position »N« must be
engaged on vehicles with automatic gearbox.
♦ When conducting the test, observe the specifications provided
by the manufacturer of the test rig.

Note

The brake regulation systems do not function when ignition is off.

2.2 Checking vehicles with front-wheel drive

The brake test must be performed on a single-axle roller dyna‐
mometer.
The testunless
speed must not exceed 6 km/h.
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The test stands approved by Škoda comply with these conditions.

2. Brake inspection 3
 Citigo 2012 ➤
Brake systems - Edition 11.2012

45 – Anti-lock brake system

1 Antilock braking system (ABS)
General instructions for ABS ⇒ page 4
Repair instructions for repair work on ABS ⇒ page 5
Vehicle diagnosis, measurement and information system
⇒ page 6
Indication of faults by means of warning lights ⇒ page 7

1.1 General instructions for ABS

The following configurations are possible on vehicles with ABS
from TRW:
♦ ABS
♦ ABS/ESC
The ABS brake system is divided diagonally. The brake servo
assistance is provided pneumatically by the vacuum brake servo
unit.
Faults in the ABS do not influence the brake system and servo
assistance. The conventional brake system remains fully func‐
tional also without ABS. Take into account a change in braking
behaviour. The rear wheels can block quite early on after the ABS
warning light lights up!
ABS layout in left-hand drive vehicle:
1 - Brake servo unit
2 - Hydraulic unit and control unit

ABS layout in right-hand drive vehicle:

1 - Brake servo unit
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2 - Hydraulic unit and control unit by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
unless authorised
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

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

 Citigo 2012 ➤
Brake systems - Edition 11.2012

The control unit -1- and the hydraulic unit -2- form a single unit.
Hydraulic pump -3- must not be separated from hydraulic unit.

1.2 Repair instructions for repair work on

ABS
♦ Before commencing work on the ABS systems it is necessary
to interrogate the fault memory in order to check complaints
and conduct specific fault finding.
♦ Do not separate plug connections unless the ignition is switch‐
ed off.
♦ Before commencing work on the ABS systems, switch off the
ignition and disconnect the earth strap at the battery ⇒ Elec‐
trical System; Rep. gr. 27 .
♦ If the battery earth strap is disconnected and connected, carry
out additional operations ⇒ Electrical System; Rep. gr. 27 .
♦ Welding work using electric welding equipment may affect the
ABS system.
♦ Before commencing welding work using electrical welding
tool:
– Disconnect the cable from the negative terminal of the battery
and cover the negative terminal.
– Connect the earth connection of the electric welding tool di‐
rectly to the part to be welded. There must not be any electri‐
cally insulated parts between the earth connection and the
welding point.
– Electronic control units and electrical wiring must not touch the
earth connection or the welding electrode.
♦ During painting operations, the electronic control unit can be
exposed to a maximum temperature of 95°C for only a short
period, and to a maximum of 85°C for longer periods (approx.
2 hours).
♦ Do not drive the vehicle if the connector is unplugged from the
control unit.
♦ Absolute cleanliness is required when working on the anti-lock
brake system. It is not permitted to use any products which
contain mineral oil, such as oils, greases etc.
♦ Thoroughly clean all unions and the adjacent areas before
loosening. Do not use aggressive cleaning agents such as
brake cleanser, petrol, thinners or similar.
♦ Place removed parts on a clean surface and cover.
♦ Carefully cover or seal opened components if the repairs are
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
not carried out immediately (use plugswith
from repair
respect to the kit 1HO 698
correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
311 A).
♦ Do not use fluffy cloths.

1. Antilock braking system (ABS) 5

 Citigo 2012 ➤
Brake systems - Edition 11.2012

♦ Remove spare parts from their wrapping immediately before

fitting.
♦ Use only genuine wrapped parts.
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ Ensure that no brake fluid is able to flow into the connectors.
♦ Observe the relevant instructions when handling brake fluid
⇒ page 72 .
♦ After completing work which involved opening the brake sys‐
tem, bleed brake system with brake filling and bleeding de‐
vice , e. g. -VAS 5234- , ⇒ page 72 .
♦ During the final road test, ensure that at least one controlled
brake application is performed (pulsing must be felt on the
brake pedal).

1.3 Vehicle Diagnosis, Measurement and

Information System
Connecting -Fahrzeugdiagnosetester- and selecting function.
Special tools and workshop equipment required
♦ Vehicle diagnosis tester -VAS-

WARNING

♦ For test drives, the test and measuring equipment must

always be fastened to the rear seat.
♦ These devices may be operated only by a passenger while
the vehicle is in motion.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

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

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Connect the connector of the diagnosis cable to the diagnostic

connection -arrow-.
– Switch on -Fahrzeugdiagnosetester- .
The -Fahrzeugdiagnosetester- is ready for operation when the
selector buttons for the operating modes are displayed on the
screen.
– Switch on ignition.
– Select Targeted fault finding on the screen.
– Select in sequence:
♦ Marking
♦ Type
♦ Model year
♦ Body version
♦ Engine identification characters
– Confirm the data entered.
Wait until tester has read all control units in vehicle.
– Press skip and select the function “select functions/compo‐
nents”.
– Select “chassis” on the display.
– Select “brake system” on the display.
– Select “01 Self-diagnosis system …” shown on the display.
– Select “01 Anti-lock brake system…” shown on the display.
– Select the “function” shown on the display.
All possible functions for the anti-lock brake system installed in
the vehicle will then be displayed.
– Select the requested function on the display.

1.4 Indication of faults by means of warning

lights
Pos. Denomination
1 Warning light for electronic stability control ESC
2 ABS warning light -K47-
3 Warning light for traction control TC
4 Brake system warning light -K118-

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Antilock braking system (ABS) 7

 Citigo 2012 ➤
Brake systems - Edition 11.2012

Warning light for electronic stability control ESC

After the ignition is switched on, the warning light for electronic
stability control ESC -1- lights up for a few seconds.
♦ If the warning light for electronic stability control ESC does not
light up during the automatic test sequence, the warning light
for electronic stability control ESC is defective, carry out ⇒
electrical test
♦ If the warning light for electronic stability control ESC does not
go out after the ignition is switched on and after completion of
the test sequence, the causes of the fault may be:
a - an ESC fault is present
b - an ABS fault is present
c - a fault in the actuation of the warning light for electronic stability
control ESC ⇒ Current flow diagrams, Electrical fault finding and
Fitting locations.

Note

Because ESC and ABS work together, the warning light for elec‐
tronic stability control ESC also lights up in case of failure of the
ABS system.

If the warning light for electronic stability control ESC flashes dur‐
ing driving, the ESC system is operating in regulating mode.

ABS warning light -K47-

After the ignition is switched on, the ABS warning light -K47- -2-
lights up for a few seconds.
♦ If the ABS warning light -K47- does not light up during the au‐
tomatic test sequence, the ABS warning light -K47- is defec‐
tive, carry out ⇒ electrical test
♦ If the ABS warning light -K47- does not go out after the ignition
is switched on and after completion of the test sequence, the
causes of the fault may be:
a - an ABS fault is present

WARNING

If an ABS fault is present, the anti-lock brake system remains

switched off while the conventional brake system remains fully
operational.

b - a sporadic fault existed on an ABS wheel speed sensor after

the last vehicle start
In this case the ABS warning light -K47- goes out automatically
after restarting the vehicle and after a speed above 20 km/h is
reached.
c - the connection from the dash panel insert to the ABS control
unit -J104- is interrupted ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
d - the dash panel insert is defective

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

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

 Citigo 2012 ➤
Brake systems - Edition 11.2012

Warning light for traction control TC

After the ignition is switched on, the warning light for traction con‐
trol TC -3- lights up for a few seconds.
♦ If the warning light for traction control TC does not light up
during the automatic test sequence, the warning light for trac‐
tion control TC is defective, carry out ⇒ electrical test
♦ If the warning light for traction control TC does not go out after
the ignition is switched on and after completion of the test se‐
quence or glows during the driving operation, there is a fault
in the TC system.
If the warning light for traction control TC flashes during driving,
the TC system is operating in regulating mode.

Note

Because TC and ABS work together, the warning light for traction
control TC also lights up in case of failure of the ABS system.

Brake system warningProtected

light -K118-
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
After the ignition is switched on,tothe
with respect brake system
the correctness warning
of information light -Copyright by ŠKODA AUTO A. S.�
in this document.
K118- -4- lights up for a few seconds.
♦ If the brake system warning light -K118- does not light up dur‐
ing the automatic test sequence, the brake system warning
light -K118- is defective, carry out ⇒ electrical test .
♦ If the brake system warning light -K118- does not go out after
switching on the ignition or glows during the driving operation,
the following can be the causes of the fault:
a - Brake fluid level in brake fluid reservoir too low (warning light
flashes)
– Check brake fluid level and top up with brake fluid.
b - ABS fault with effect on the function of the brake system, at
the same time the ABS warning light -K47- lights up
c - There is a fault in the wiring to the brake system warning light
-K118- ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations.

ABS warning light -K47- and Brake system warning light -K118-
♦ If the ABS warning light -K47- (-2-) and the brake system
warning light -K118- (-4-) light up, the ABS system with effect
on the function of the brake system is defective. One must
reckon with a somewhat changed braking characteristic.

WARNING

Once the ABS warning light -K47- and the brake system warn‐
ing light -K118- have lit up, then the rear wheels can lock quite
early on when braking.

1. Antilock braking system (ABS) 9

 Citigo 2012 ➤
Brake systems - Edition 11.2012

2 Fitting location overview

ABS ⇒ page 10 .
ABS/ESC ⇒ page 11 .

2.1 ABS

1 - ABS control unit -J104-

❑ Location: on hydraulic
unit, on left in engine
compartment, under
battery tray.
❑ Do not disconnect the
plug connection before
successfully completing
the self-diagnosis.
Switch off the ignition
before disconnecting
the plug connection.
❑ removing and installing
⇒ page 14
2 - ABS hydraulic unit -N55-
The hydraulic unit consists of
these components:
❑ ABS return flow pump -
V39-
❑ Valve block (contains in‐
let and outlet valves).
❑ The ABS return flow
pump -V39- and the
valve block must not be
separated from each
other
❑ removing and installing
⇒ page 14
3 - ABS warning light -K47-
❑ Fitting location: Protected
in the by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
dash panel insert
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
4 - Traction control warning
light
❑ Fitting location: in the
dash panel insert
5 - Brake system warning light -K118-
❑ Fitting location: in the dash panel insert
6 - Parking brake warning lamp -K139-
❑ Fitting location: in the dash panel insert
7 - Diagnostic connection
❑ Fitting location: cover of driver's footwell
8 - Brake light switch -F-
❑ Including brake pedal switch -F47- .
❑ removing and installing ⇒ page 53
9 - Front right/left wheel speed sensors -G45- / -G47-
❑ removing and installing ⇒ page 21

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

 Citigo 2012 ➤
Brake systems - Edition 11.2012

10 - Rear right/left wheel speed sensors -G44- / -G46-

❑ removing and installing (drum brake) ⇒ page 23
11 - Wheel hub with wheel bearing
❑ the ABS sensor ring is installed in wheel bearing
12 - Wheel hub with wheel bearing
❑ the ABS sensor ring is installed in wheel bearing

2.2 ABS/ESC

1 - ABS control unit -J104-

❑ Location: on hydraulic
unit, on left in engine
compartment, under
battery tray.
❑ Do not disconnect the
plug connection before
successfully completing
the self-diagnosis.
Switch off the ignition
before disconnecting
the plug connection.
The following components are
integrated in the control unit:
♦ Lateral acceleration sender
-G200-
♦ Yaw rate sender -G202-Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ Longitudinal acceleration with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
sender -G251- (depending
on equipment fitted)
❑ removing and installing
⇒ page 14
2 - ABS hydraulic unit -N55-
The hydraulic unit consists of
these components:
❑ ABS return flow pump -
V39-
❑ Brake pressure sender -
G201-
❑ Valve block (contains in‐
let and outlet valves).
❑ The ABS return flow
pump -V39- and the
valve block must not be
separated from each
other
❑ removing and installing ⇒ page 14
3 - Warning light for ESC
❑ Fitting location: in the dash panel insert
4 - ABS warning light -K47-
❑ Fitting location: in the dash panel insert
5 - Brake system warning light -K118-
❑ Fitting location: in the dash panel insert

2. Fitting location overview 11

 Citigo 2012 ➤
Brake systems - Edition 11.2012

6 - Parking brake warning lamp -K139-

❑ Fitting location: in the dash panel insert
7 - Brake light switch -F-
❑ Including brake pedal switch -F47- .
❑ removing and installing ⇒ page 53
8 - Diagnostic connection
❑ Fitting location: cover of driver's footwell
9 - Steering angle sender -G85-
❑ Location: on steering column between steering wheel and steering column switch.
❑ Observe installation instructions
⇒ page 23
10 - Front right/left wheel speed sensors -G45- / -G47-
❑ removing and installing ⇒ page 21
11 - Wheel hub with wheel bearing
❑ the ABS sensor ring is installed in wheel bearing
12 - Rear right/left wheel speed sensors -G44- / -G46-
❑ removing and installing (drum brake) ⇒ page 23
13 - Wheel hub with wheel bearing
❑ the ABS sensor ring is installed in wheel bearing

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

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

 Citigo 2012 ➤
Brake systems - Edition 11.2012

3 Control unit and hydraulic unit

Summary of components ⇒ page 13 .
Removing and installing control unit and hydraulic unit
⇒ page 14 .
Connecting brake lines to hydraulic unit ⇒ page 19 .

3.1 Summary of components

1 - Brake servo unit

❑ removing and installing
⇒ page 58
2 - Brake line, 14 Nm
❑ to front right brake cali‐
per
❑ Marking on the hydraul‐
ic unit -FR-
❑ With thread M10 x 1
3 - Brake line, 14 Nm
❑ To rear left wheel brake
cylinder
❑ Marking on the hydraul‐
ic unit -RL-
❑ With thread M12 x 1
4 - Brake line, 14 Nm
❑ To rear right wheel
brake cylinder
❑ Marking on the hydraul‐
ic unit -RR-
❑ With thread M10 x 1Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
5 - Brake line, 14 Nm with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

❑ To front left brake cali‐

per.
❑ Marking on the hydraul‐
ic unit -FL-
❑ With thread M12 x 1
6 - ABS control unit -J104-
❑ Remove and install ABS
hydraulic unit -N55- with
ABS control unit -J104-
⇒ page 14
7 - ABS hydraulic unit -N55-
❑ The ABS return flow pump -V39- and the valve block must not be separated from each other
❑ When renewing the hydraulic unit, always seal the old part with plugs from repair kit -1H0 698 311 A- .
❑ Remove and install ABS hydraulic unit -N55- with ABS control unit -J104- ⇒ page 14
8 - Support
❑ Assignment ⇒ Electronic Catalogue of Original Parts
9 - Rubber damper
10 - Screw, 8 Nm
11 - Brake line, 14 Nm
❑ Master brake cylinder/push rod piston circuit to hydraulic unit

3. Control unit and hydraulic unit 13

 Citigo 2012 ➤
Brake systems - Edition 11.2012
❑ Marking on the hydraulic unit -HZ2-
❑ With thread M12 x 1
12 - Brake line, 14 Nm
❑ Master brake cylinder/floating piston circuit to hydraulic unit
❑ Marking on the hydraulic unit -HZ1-
❑ With thread M12 x 1

3.2 Removing and installing control unit and

hydraulic unit
Removing and installing control unit and hydraulic unit, LHD - left-
hand drive ⇒ page 14 .
Removing and installing control unit and hydraulic unit, RHD -
right-hand drive ⇒ page 17 .

3.2.1 Removing and installing control unit and

hydraulic unit, LHD - left-hand drive
Special tools and workshop equipment required
♦ Brake pedal load , e.g. -V.A.G 1869/2-
♦ Brake filling and bleeding device , e. g. -VAS 5234-
Sealing plugs repair kit part number 1H0 698 311 A
Fitting location:
The control unitbyiscopyright.
Protected boltedCopying
to theforhydraulic unit and
private or commercial is located
purposes, in part or inon
whole, is not permitted
left in theunless
engine compartment,
authorised by ŠKODA AUTOunder the AUTO
A. S. ŠKODA battery
A. S. tray.
does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

WARNING

The brake lines around the hydraulic unit must not be bent!

Removing:
– Read out and note the actual control unit coding.
– On models fitted with a coded radio, pay attention to the cod‐
ing, determine if necessary.
– Remove battery ⇒ Electrical System; Rep. gr. 27 .
– Unscrew the engine control unit from the bracket and lay to
the side ⇒ Engine; Rep. gr. 24 .
– Remove battery tray ⇒ Electrical System; Rep. gr. 27 .
– Remove air filter ⇒ Engine; Rep. gr. 24 .
– Place sufficient lint-free cloths in area of engine and gearbox.
– Use the brake filling and bleeding device , e.g. -VAS 5234- ,
to drain as much brake fluid as possible from the brake fluid
reservoir.

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

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Press locking slide -2- downwards in -direction of arrow-.

– Then press retaining bar -1- downwards in
-direction of arrow- in order to unlock connector -3-.
– Pull connector towards front off control unit.

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

– Connect bleed bottle bleed hose -1- to bleed valve of front left
brake caliper.
– Open vent valve.
– Connect bleed hose of bleed bottle to bleed valve of rear left
wheel brake cylinder.
– Open vent valve.
– Depress brake pedal at least
unless 60 mm
authorised using brake
AUTO pedalAUTO
A. S. ŠKODA de‐ A. S. does not guarantee or accept any liability
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
by ŠKODA
pressor -V.A.G 1869/2- with
. respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Close front left and rear left bleeder valve.
– Do not remove brake pedal depressor -V.A.G 1869/2- .
– Place sufficient non-fluffing cloths under the control unit and
the hydraulic unit.
Make sure that no brake fluid gets onto the contacts.
– Mark brake lines from hydraulic unit -A and B- to brake master
cylinder.

3. Control unit and hydraulic unit 15

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Then unscrew brake lines -A and B- from brake master cylin‐

der and hydraulic unit and immediately seal brake lines with
sealing plugs from repair kit part number 1H0 698 311 A.
– Mark remaining brake lines (to brake calipers) -1 to 4-, un‐
screw them from hydraulic unit and immediately seal brake
lines with sealing plugs from repair kit part number
1H0 698 311 A.

– Pull ABS hydraulic unit -N55- -1- together with ABS control unit
-J104- and bracketProtected
upwards in -direction of arrow- off welded
by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
studs. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Installing:

Note

♦ Remove sealing plugs from new hydraulic unit only when the
corresponding brake line is to be fitted.
♦ If the sealing plugs were already removed from the hydraulic
unit, then brake fluid may escape and adequate filling and
bleeding can no longer be guaranteed.
♦ When installing, pay attention that the damper rubbers are
correctly fitted in the bracket.

Further installation occurs in reverse order.

– Remove brake pedal depressor -V.A.G 1869/2- .
– Bleeding brake system ⇒ page 72 .
– Code the ABS control unit -J104- with the ⇒ Vehicle diagnostic
tester in the function “Guided fault finding”.
– Code radio.
Tightening torques:
Bracket to ABS unit: 8 Nm
Brake lines to ABS unit:
Thread M 10 x 1 14 Nm
Thread M 12 x 1 14 Nm

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

 Citigo 2012 ➤
Brake systems - Edition 11.2012

3.2.2 Removing and installing control unit and

hydraulic unit, RHD - right-hand drive
Special tools and workshop equipment required
♦ Brake pedal load , e.g. -V.A.G 1869/2-
♦ Brake filling and bleeding device , e. g. -VAS 5234-
Sealing plugs repair kit part number 1H0 698 311 A
Fitting location:
The control unit is bolted to the hydraulic unit and is located on
left in the engine compartment, under the battery tray.

WARNING

The brake lines around the hydraulic unit must not be bent!

Removing:
– Read out and note the actual control unit coding.
– On models fitted with a coded radio, pay attention to the cod‐
ing, determine if necessary.
– Remove battery ⇒ Electrical System; Rep. gr. 27 .
– Unscrew the engine control unit from the bracket and lay to
the side ⇒ Engine; Rep. gr. 24 .
– Remove battery tray ⇒ Electrical System; Rep. gr. 27 .
– Remove air filter ⇒ Engine; Rep. gr. 24 .
– Place sufficient lint-free cloths in area of engine and gearbox.
– Use the brake filling and bleeding device , e.g. -VAS 5234- ,
to drain as much brake fluid as possible from the brake fluid
reservoir.

– Press locking slide -2- downwards in -direction of arrow-.

– Then press retaining bar -1- downwards in
-direction of arrow- in order to unlock connector -3-.
– Pull connector towards front off control unit.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

3. Control unit and hydraulic unit 17

 Citigo 2012 ➤
Brake systems - Edition 11.2012

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

– Connect bleed bottle bleed hose -1- to bleed valve of front left
brake caliper.
– Open vent valve.
– Connect bleed hose of bleed bottle to bleed valve of rear left
wheel brake cylinder.
– Open vent valve.
– 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 non-fluffing cloths under the control unit and
the hydraulic unit.
Make sure that no brake fluid gets onto the contacts.
– Mark brake lines from hydraulic unit -A and B- to brake master
cylinder.

– Then unscrew brake lines -A and B- from brake master cylin‐

der and hydraulic unit and immediately seal brake lines with
sealing plugs from repair kit part number 1H0 698 311 A.
– Mark remaining brake lines (to brake calipers) -1 to 4-, un‐
screw them from hydraulic unit and immediately seal brake
lines with sealing plugs from repair kit part number
1H0 698 311 A.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

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

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Pull ABS hydraulic unit -N55- -1- together with ABS control unit
-J104- and bracket upwards in -direction of arrow- off welded
studs.
Installing:

Note

♦ Remove sealing plugs from new hydraulic unit only when the
corresponding brake line is to be fitted.
♦ If the sealing plugs were already removed from the hydraulic
unit, then brake fluid may escape and adequate filling and
bleeding can no longer be guaranteed.
♦ When installing, pay attention that the damper rubbers are
correctly fitted in the bracket.

Further installation occurs in reverse order.

– Remove brake pedal depressor -V.A.G 1869/2- .
– Bleeding brake system ⇒ page 72 .
– Code the ABS control unit -J104- with the ⇒ Vehicle diagnostic
tester in the function “Guided fault finding”.
– Code radio.
Tightening torques:
Bracket to ABS unit: 8 Nm
Brake lines to ABS unit:
Thread M 10 x Protected
1 by copyright. Copying for private or commercial14 Nm in part or in whole, is not permitted
purposes,
Thread M 12 xunless
1withauthorised 14 NmCopyright by ŠKODA AUTO A. S.�
by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
respect to the correctness of information in this document.

3.3 Connecting brake lines to hydraulic unit

Connecting brake lines to hydraulic unit, LHD - left-hand drive
⇒ page 19 .
Connecting brake lines to hydraulic unit, RHD - right-hand drive
⇒ page 20 .

3.3.1 Connecting brake lines to hydraulic unit,

LHD - left-hand drive
A - Push rod piston circuit of master brake cylinder to hydraulic
unit
B - Floating piston circuit of master brake cylinder to hydraulic unit
1 - Hydraulic unit to front right brake caliper
2 - Hydraulic unit to rear left wheel brake cylinder
3 - Hydraulic unit to rear right wheel brake cylinder
4 - Hydraulic unit to front left brake caliper

3. Control unit and hydraulic unit 19

 Citigo 2012 ➤
Brake systems - Edition 11.2012

Markings on hydraulic unit:

A - From hydraulic unit to primary piston circuit of brake master
cylinder.
- Marking on the hydraulic unit -HZ2-
B - From hydraulic unit to secondary piston circuit of brake master
cylinder.
- Marking on the hydraulic unit -HZ1-
1 - Hydraulic unit to front right brake caliper
- Marking on the hydraulic unit -FR-
2 - Hydraulic unit to rear left brake caliper/wheel brake cylinder
- Marking on the hydraulic unit -RL-
3 - Hydraulic unit to rear right brake caliper/wheel brake cylinder
- Marking on the hydraulic unit -RR-
4 - Hydraulic unit to front left brake caliper
- Marking on the hydraulic unit -FL-

3.3.2 Connecting brake lines to hydraulic unit,

RHD - right-hand drive
A - Push rod piston circuit of master brake cylinder to hydraulic
unit
B - Floating piston circuit of master brake cylinder to hydraulic unit
1 - Hydraulic unit to front right brake caliper
2 - Hydraulic unit to rear left wheel brake cylinder
3 - Hydraulic unit to rear right wheel brake cylinder
4 - Hydraulic unit to front left brake caliper
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Markings on hydraulic unit: with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

A - From hydraulic unit to primary piston circuit of brake master

cylinder.
- Marking on the hydraulic unit -HZ2-
B - From hydraulic unit to secondary piston circuit of brake master
cylinder.
- Marking on the hydraulic unit -HZ1-
1 - Hydraulic unit to front right brake caliper
- Marking on the hydraulic unit -FR-
2 - Hydraulic unit to rear left brake caliper/wheel brake cylinder
- Marking on the hydraulic unit -RL-
3 - Hydraulic unit to rear right brake caliper/wheel brake cylinder
- Marking on the hydraulic unit -RR-
4 - Hydraulic unit to front left brake caliper
- Marking on the hydraulic unit -FL-

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

 Citigo 2012 ➤
Brake systems - Edition 11.2012

4 Sensors
Assembly overview - speed sensor on front axle ⇒ page 21 .
Removing and installing speed sensor on the front axle
⇒ page 21 .
Assembly overview - speed sensor on rear axle ⇒ page 22 .
Removing and installing speed sensor on the rear axle
⇒ page 23 .
Removing and installing steering angle sender ⇒ page 23 .
Removing and installing yaw rate sender and lateral acceleration
sender ⇒ page 23 .

4.1 Assembly overview - speed sensor on front axle

1 - Drive shaft
2 - Wheel-bearing housing
3 - Screw, 8 Nm
4 - Wheel speed sensor
❑ Before inserting sensor,
clean hole inner surface
and coat with high-tem‐
perature paste
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
G 052 112unless
A3. authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ removing and installing
⇒ page 21
5 - Brake disc
6 - Wheel hub
7 - Circlip
8 - Wheel bearing
❑ the ABS sensor ring is
installed in wheel bear‐
ing
❑ pressing out and press‐
ing in ⇒ Axles, steering;
Rep. gr. 40
9 - Screws, 12 Nm
10 - Cover plate
11 - Screw, 4.5 Nm
12 - Self-locking twelve-point
nut
❑ Tightening torque ⇒
Axles, steering; Rep. gr.
40

4.2 Removing and installing wheel speed

sensor on the front axle
Removing:
– Raise vehicle.

4. Sensors 21
 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Disconnect plug connection -1- for ABS wheel speed sensor

cable from wheel speed sensor.
– Unscrew Allan screw -3-.
– Remove the ABS speed sensor -2- from the wheel-bearing
housing.
Installing:
– Before inserting speed sensor, clean hole inner surface and
coat speed sensor all-round with high-temperature paste
G 052 112 A3.
– Insert the wheel speed sensor in the bore of the wheel-bearing
housing and tighten the screw to 8 Nm.
– Connect the wheel speed sensor with the wheel speed sensor
cable.
– Turn steering to full left and right lock and check clearance to
speed sensor wire.

4.3 Assembly overview - speed sensor on rear axle

1 - Axle body
2 - Screw, 8 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
3 - ABS wheel speed sensor with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

❑ Before inserting sensor,

clean hole inner surface
and coat with high-tem‐
perature paste G 052
112 A3.
❑ removing and installing
⇒ page 23
4 - Brake line
5 - Axle stud
6 - Hand-brake cable
7 - Hexagon bolt
❑ Tightening torque ⇒
Axles, steering; Rep. gr.
42
8 - Screw, 8 Nm
9 - Brake drum
❑ Reset brake before re‐
moving brake drum
⇒ page 32 .
10 - Cap
❑ extracting and inserting
⇒ Axles, steering; Rep.
gr. 42
11 - Self-locking twelve-point
nut
❑ replace after each re‐
moval ⇒ Axles, steer‐

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

 Citigo 2012 ➤
Brake systems - Edition 11.2012

ing; Rep. gr. 42

12 - Wheel hub with wheel bearing
❑ the ABS sensor ring is installed in wheel bearing
❑ removing and installing ⇒ Axles, steering; Rep. gr. 42
13 - Brake carrier with brake shoes
❑ Reset brake before removing brake drum ⇒ page 32 .

4.4 Removing and installing wheel speed

sensor on the rear axle
Removing:
– Raise vehicle.
– Separate plug connection -1- wheel speed sensor cable/wheel
speed sensor.
– Release the screw -2- from the axle stud.
– Pull ABS speed sensor out of stub axle.
Installing:
– Before inserting speed sensor, clean hole inner surface and
coat speed sensor all-round with high-temperature paste
G 052 112 A3.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Insert the wheel speed sensor unless
in with
theauthorised
bore ofby the
ŠKODAaxle stud
AUTO A. S.and
ŠKODA AUTO A. S. does not guarantee or accept any liability
respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
tighten the screw to 8 Nm.
– Connect the wheel speed sensor with the wheel speed sensor
cable.

4.5 Removing and installing steering angle

sender
The steering angle sender -G85- is installed between the steering
wheel and the steering column switch.
Removing and installing
⇒ Electrical System; Rep. gr. 94 .
– Subsequently perform a basic setting of the steering angle
sender -G85- .
Connecting -Fahrzeugdiagnosetester- and selecting functions
⇒ page 6 .

4.6 Removing and installing yaw rate send‐

er and lateral acceleration sender
The lateral acceleration sender -G200- , the yaw rate sender -
G202- and the longitudinal acceleration sender -G251- (depend‐
ing on the equipment fitted) are installed in the control unit.
It is not possible to replace these parts separately.
– Removing and installing ABS control unit -J104- ⇒ page 14 .

4. Sensors 23
 Citigo 2012 ➤
Brake systems - Edition 11.2012

46 – Brakes - mechanism
1 Repairing front wheel brake
Changing the brake pads of the front brake - Mounting instruc‐
tions ⇒ page 24 .
Assembly overview - front brake ⇒ page 24 .
Removing and installing brake pads ⇒ page 26 .
Removing and installing brake caliper ⇒ page 28 .

1.1 Changing the brake pads of the front

brake - Mounting instructions
When changing the pad, observe the following:
– Check protective collar of brake caliper piston.
Replace the protective collar if damaged.
When replacing the collar:
– Check the contact surfaces of the brake piston and the brake
caliper for any dirt (oxydation).
Carefully clean the piston as well as the brake caliper if dirty and
replace the sealing sleeve.
– Check the brake piston and the brake caliper (corrosion,
grooves on the outside of the cylinder surface), replace the
brake caliper completely if damaged.
For brake caliper piston, press into the initial position:
– Check if the piston can be slightly pressed into the brake cal‐
iper.
If the piston cannot be slightly pressed into the brake caliper:
– Check and clean the brake piston as well as the brake caliper,
replace sealing sleeve and protective collar.
Replace the brake caliper completely if damaged.

1.2 Assembly overview - front brakes

Note

♦ Observe the instructions for changing theunless

padauthorised
⇒bypage
Protected 24Copying
copyright. . for private or commercial purposes, in part or in whole, is not permitted
by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ After replacing the brake pads, depress brake pedal firmly several times when the vehicle is stationary to
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

ensure the brake pads are properly seated in their normal operating position.
♦ Use the brake pedal load , e.g. -V.A.G 1869/2- before removing a brake caliper or separating a brake hose
from the brake caliper.
♦ Use a bleeding container that only comes into contact with the brake fluid to drain brake fluid from the brake
fluid reservoir. Brake fluid is toxic and must never be sucked up by mouth!
♦ Already used brake fluid must never be used again.
♦ Tightening torque of the wheel screws: 120 Nm.

Assembly overview - brake caliper FS III:

24 Rep. gr.46 - Brakes - mechanism

 Citigo 2012 ➤
Brake systems - Edition 11.2012

1 - Brake disc
❑ Assignment, dimen‐
sions and wear limit
⇒ page 1
❑ always replace axle-
wise
❑ unscrew the brake cali‐
per before removing
❑ Do not use force to sep‐
arate the brake discs
from the wheel hub, if
necessary use rust sol‐
vent; as you could oth‐
erwise damage the
brake discs.
2 - Screw, 4.5 Nm
3 - Brake pads
❑ Thickness, wear limit
⇒ page 1
❑ Inspect thickness
⇒ Maintenance ; Book‐
let Citigo
❑ always replace axle-
wise
❑ do not unscrew the
brake line when replac‐
ing the brake pad
❑ removing and installing
⇒ page 26
❑ do not interchange the
inside and outside brake
pads
4 - Brake caliper
❑ Do not disconnect brake

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Repairing front wheel brake 25

 Citigo 2012 ➤
Brake systems - Edition 11.2012

hose when changing

brake pads.
❑ removing and installing ⇒ page 28
❑ Repairing ⇒ page 47 .
5 - Guide bolt, 30 Nm
6 - Cap
❑ removing
7 - Tensioning sleeve
8 - Brake hose with supports, hollow screw and gasket rings
❑ must be replaced completely, do not dismantle
❑ Tightening torque: 35 Nm
❑ do not unscrew when replacing the brake pad
9 - Wheel hub with wheel bearing
❑ pressing out and pressing in ⇒ Axles, steering; Rep. gr. 40
10 - Screws, 12 Nm
11 - Cover plate
12 - Wheel-bearing housing
❑ with integrated brake carrier
❑ Lightly grease brake pad guiding surfaces with lithium grease G 052150 A2.
13 - ABS wheel speed sensor
❑ Before inserting sensor, clean hole inner surface and coat with high-temperature paste G 052 112 A3.
14 - Screw, 8 Nm

1.3 Removing and installing brake pads

Special tools and workshop equipment required
♦ Piston jig -MP9-403-
Observe the instructions for changing the pad ⇒ page 24 .
Removing:
– Remove wheels.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Notewith respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

♦ When removing mark the brake pads (inner, outer) you intend
to keep using. Install in the same location, as otherwise this
may cause uneven braking!
♦ Do not unscrew the brake hose when replacing the brake pad.

– Remove cover caps.

26 Rep. gr.46 - Brakes - mechanism

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Unscrew both guide bolts of the brake caliper -arrows- from

the wheel-bearing housing and remove.
– Remove brake caliper and secure with wire so that weight of
brake caliper does not strain or damage brake hose.
– Take the brake pads out of the brake caliper.
Cleaning:

WARNING

Do not blow out brake system with compressed air; the dust
constitutes a health hazard!

– Thoroughly clean guiding surface for brake pads on brake

carrier and remove corrosion.
– Clean the brake caliper.
Only use alcohol to clean the brake caliper.
Installing:
Drain the brake fluid from the brake fluid reservoir before the pis‐
ton is pushed with the piston jig into the cylinder. Otherwise brake
fluid can flow out and lead to damage if brake fluid was added in
the meantime.
– Lightly grease guiding surface for brake pads on brake carrier
with lithium grease G 052150 A2.

– Press the piston into the brake caliper housing using the piston
resetting jig -MP9-403- .
– Insert brake pads into brake caliper and piston.

– Insert brake pad with “piston side” written on supporting plate

into brake piston.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

27
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
1. Repairing front wheel brake
 Citigo 2012 ➤
Brake systems - Edition 11.2012

– First position brake caliper at bottom -arrow- of brake carrier.

– Fit both guide bolts of the brake caliper together with the brake
caliper onto the wheel-bearing housing and screw on.
– Insert both caps.
– Fit wheels.

Note

♦ After every brake pad change, depress brake pedal firmly sev‐
eral times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
♦ Check brake fluid level after replacing the brake pads.

Tightening torque:
Guide bolts to brake carrier 30 Nm

1.4 Removing and installing brake caliper

Special tools and workshop equipment required
♦ Brake pedal load , e.g. -V.A.G 1869/2-
Removing:
The procedure applies only for the replacement or for the follow‐
ing repair work on the brake caliper.
– Remove wheels.
– Attach the bleeder hose of the bleeding bottle onto the vent
valve of the brake caliper and then open the bleeder valve.
– Apply brake pedal depressor -V.A.G 1869/2- .
– Close the vent valve and remove the bleeding bottle.
– Unscrew brake hose.
– Remove both caps out of the bushings of the brake caliper.
– Loosen and remove the two guide bolts from the brake caliper.
– Pull off brake caliper from brake carrier.
– Take out the brake pads from the brake caliper.
Installing:
• The piston is pushed back.
– Insert brake pads into brake caliper and piston.
– Insert brake pad with “piston side” written on supporting plate
into brake piston.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

28 Rep. gr.46 - Brakes - mechanism

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– First position the brake caliper with the brake pads at the bot‐
tom -arrow- of the brake carrier.
– Fit both guide bolts of the brake caliper together with the brake
caliper onto the wheel-bearing housing and screw on.
– Insert both caps.
– Screw the brake hose onto the brake caliper.
– Remove brake pedal load -V.A.G 1869/2- .
– Bleeding brake system ⇒ page 72 .
– Fit wheels.

Note

♦ Forcefully apply the brake pedal repeatedly to ensure the

brake pads go into their normal operating position.
♦ Inspecting the brake fluid level.

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

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Repairing front wheel brake 29

 Citigo 2012 ➤
Brake systems - Edition 11.2012

2 Repairing rear brake

Replacing the brake shoes of the rear brake - Mounting instruc‐
tions ⇒ page 30 .
Assembly overview - rear brake ⇒ page 30 .
Resetting drum brake ⇒ page 32 .
Removing and installing brake shoes ⇒ page 32 .

2.1 Replacing the brake shoes of the rear

brake - Mounting instructions
When changing the brake shoes, pay attention to the following
points:
– Check the protective collars of the wheel-brake cylinders.
Replace the wheel-brake cylinders if the protective collars are
damaged.
– Test wheel-brake cylinder for tightness ⇒ page 75 .
Replace the wheel-brake cylinder if leaking.
– Check if the pistons can be slightly pressed into the brake cal‐
iper.
If the pistons cannot be slightly pressed into the brake caliper:
– Replace the wheel-brake cylinder.
Always replace the brake shoes axle-wise.

2.2 Assembly overview - rear brakes

Note

♦ Observe the instructions when replacing the brake shoes ⇒ page 30 .

♦ After replacing the wheel-brake cylinder, brake carrier and the rear brake shoes, forcefully apply the brake
pedal several times to ensure the brake shoes go into their normal operating position.
♦ Generally tighten the brake line pipe screws to a tightening torque of 14 Nm.
♦ Use a bleeding container that only comes into contact with the brake fluid to drain brake fluid from the brake
fluid reservoir. Brake fluid is toxic and must never be sucked up by mouth!
♦ Use brake pedal load , e. g. -V.A.G 1869/2- , before removing a brake cylinder, a brake carrier or before
separating a brake line from the brake cylinder.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ Already used brake fluid must never beauthorised
unless used again.
by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ Tightening torque of the wheel screws: 120 Nm.

30 Rep. gr.46 - Brakes - mechanism

 Citigo 2012 ➤
Brake systems - Edition 11.2012

1 - Axle body
2 - Screw, 8 Nm
3 - ABS wheel speed sensor
❑ Before inserting sensor,
clean hole inner surface
and coat with high-tem‐
perature paste G 052
112 A3.
4 - Brake line, 14 Nm
5 - Axle stud
6 - Hand-brake cable
❑ Setting the hand-brake
⇒ page 40
7 - Hexagon bolt
❑ Tightening torque ⇒
Axles, steering; Rep. gr.
42
8 - Screw, 8 Nm
9 - Brake drum
❑ Assignment, dimen‐
sions and wear limit
⇒ page 1
❑ Reset brake before re‐
moving brake drum
⇒ page 32 .
❑ Clean carefully and
check for wear, dam‐
age, dimensional accu‐
racy and flawless brake
surface.
10 - Cap
❑ extracting and inserting
⇒ Axles, steering; Rep. gr. 42
11 - Self-locking twelve-point nut
❑ replace after each removal ⇒ Axles, steering; Rep. gr. 42
12 - Wheel hub with wheel bearing
❑ removing and installing ⇒ Axles, steering; Rep. gr. 42
13 - Brake carrier with brake shoes
❑ Assignment, dimensions and wear limit ⇒ page 1
❑ Inspect thickness ⇒ Maintenance ; Booklet Citigo
❑ Reset brake before removing brake drum ⇒ page 32 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

2. Repairing rear brake 31

 Citigo 2012 ➤
Brake systems - Edition 11.2012

2.3 Resetting drum brakes

– Insert a screwdriver through a wheel bolt threaded hole in the
brake drum and push the wedge upwards.

2.4 Removing and installing brake shoes

Special tools and workshop equipment required
♦ Hook -3438-
After working on the rear axle brake:
♦ Put hand-brake back.
♦ Forcefully apply the foot brake repeatedly.
Assembly overview - brake shoes:

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

32 Rep. gr.46 - Brakes - mechanism

 Citigo 2012 ➤
Brake systems - Edition 11.2012

1 - Spring plate
❑ To remove, push
against compression
spring and turn by 90°.
2 - Pressure spring
3 - Brake shoe with lever for
hand-brake
❑ removing and installing
⇒ page 32
❑ Setting the hand-brake
⇒ page 40
4 - Top retractor spring
❑ detach with the hook
-3438-
5 - Bottom retractor spring
❑ Grease contact surface
with lubricating paste
part number G 052 109
A2
6 - Tension spring
7 - Brake shoe
8 - Screw cap
❑ remove to check brake
pad thickness
9 - Tensioning sleeve
10 - Brake carrier
11 - Screw, 8 Nm
12 - Wheel-brake cylinder
❑ Observe the instruc‐
tions when replacing the
brake shoes ⇒ page 30
❑ test tightness ⇒ page 75
13 - Wedge
❑ To remove and install the brake drum, push wedge upwards through a wheel bolt hole ⇒ page 32 .
14 - Pressure rod
❑ Grease contact surface with lubricating pasteCopying
Protected by copyright. part for
number
private or G 052 109
commercial A2 in part or in whole, is not permitted
purposes,
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
15 - Locating spring with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

❑ detach with the hook -3438-

Removing:
– Remove wheels.
– Resetting brake shoes ⇒ page 32 .
– Remove securing screw to brake drum.
– Remove the brake drum.
– Remove spring cap with pressure springs.

2. Repairing rear brake 33

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Use a screwdriver to lift off the raised part of the bottom sup‐
port in -direction of the arrow-.
– Unhook the retractor spring at the bottom.
– Unhook the hand-brake cable.
– Carefully remove the brake shoes between the wheel hub and
the brake carrier.

– Clamp brake shoes in vice.

– Remove the tension spring -1- for wedge -2-.
– Remove the top retractor spring -3- with hook -3438- -A-.

– Unhook the locating spring -1- with hook -3438- -A-.

– Remove the pressure rod -2- and the wedge -3- from the brake
shoe.
Cleaning:

WARNING

Do not blow out brake system with compressed air; the dust
constitutes a health hazard!

Use only methylated spirits for cleaning the brake system.

Installing:

– Grease the contact point of the pressure rod using solid lubri‐
cant paste -G 052 109 A2- .
– Insert the locating spring -1- in the brake shoe -2- and position
the brake shoe on the pressure rod -3-

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

34 Rep. gr.46 - Brakes - mechanism

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Hook locating spring -1- with hook -3438- -A- in the pressure
rod -2-.
– Insert wedge -3-.

Note

Observe fitting location of wedge. The raised part of the wedge

-arrow- must remain visible during installation.

– Grease the contact point of the pressure rod using solid lubri‐
cant paste -G 052 109 A2- .
– Insert the brake shoe with handbrake lever in the pressure rod.
– Install the top retractor spring -3- with hook -3438- -A-.
– Hook on the tension spring -1- for wedge -2-.
– Carefully guide the brake shoes in between the wheel hub and
the brake carrier.
– Position brake shoes on the brake cylinder pistons.
– Hook the handbrake cable onto the handbrake lever.
– Grease the contact points of the bottom retractor spring on the
brake shoe with solid lubricant paste -G 052 109 A2- .
– Insert the bottom retractor spring and lever the brake shoe
across the raised part of the bottom support to the support
surface using a screwdriver.
– Insert the pressure spring with spring cap.
– Clean the centring seat of the wheel hub for the brake drum
and subsequently treat it with anti-corrosion agent -AKR 322
000- .
– Clean the centring hole of the brake drum and subsequently
treat it with anti-corrosion agent -AKR 322 000- .

Note

The anti-corrosion agent -AKR 322 000- must not get into the
threads of the wheel screws!
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Install the
with brake
respect to thedrum.
correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Activate the brake pedal forcefully several times, so that the

rear brake is adjusted.
– Setting the hand-brake ⇒ page 40 .
Tightening torques:
Brake drum to wheel hub 8 Nm

2. Repairing rear brake 35

 Citigo 2012 ➤
Brake systems - Edition 11.2012

3 Handbrake
Handbrake - Assembly overview ⇒ page 36 .
Removing and installing the rear handbrake cable ⇒ page 37 .
Setting the hand-brake ⇒ page 40 .

3.1 Handbrake - Assembly overview

1 - Push button
❑ Pulling off ⇒ page 37
❑ Will be destroyed when
pulling off; must be re‐
newed.
❑ push onto parking brake
lever push rod and en‐
sure both locking lugs
are engaged by pulling
slightly
2 - Covering for the hand brake
lever
❑ To remove, first pull off
push button
⇒ page 37 .
❑ Lever up release tab in
rear lower area of han‐
dle with a screwdriver
❑ then pull off forwards
3 - Adjusting nut
❑ Setting the hand-brake:
❑ Vehicles with drum
brakes ⇒ page 40 .
4 - Compensating clamp
5 - Handbrake lever
❑ Removing the centre
console ⇒ Body Work;
Rep. gr. 68
6 - Hexagon nut, 23 Nm
7 - Parking brake switch -F321-
8 - Rubber grommet
9 - Right guide tube
10 - Left guide tube
11 - Handbrake cable
❑ removing and installing ⇒ page 37

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

36 Rep. gr.46 - Brakes - mechanism

 Citigo 2012 ➤
Brake systems - Edition 11.2012

Removing push button

Note

Will be destroyed when removing; must be renewed.

3.2 Removing and installing the rear hand‐

brake cable
Removing:
– Remove the centre console ⇒ Body Work; Rep. gr. 68 .
– Put hand-brake back.
– Loosen adjustment nut -arrow- until handbrake cable can be
unhooked from compensator.
– Raise vehicle.
– Remove wheel.
– Remove drum brake. Reset brake prior to removal
⇒ page 32 .

– Unhook the handbrake cable from the handbrake lever.

– Pull handbrake cable out of brake carrier.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

3. Handbrake 37
 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Clip handbrake cable -1- out of retainer on axle body -arrow-.

– Unhook handbrake cable from retainers -arrows-.

– Pull handbrake cable -1- in direction of arrow out of guide tube

-2-.
Installing:

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Fit handbrake cable -1- in direction of arrowwith
into guide
respect to thetube
correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
-2-.
– Insert handbrake cable into brake carrier.

38 Rep. gr.46 - Brakes - mechanism

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Hook the handbrake cable into the handbrake lever.

– Install brake drum.

– Clip handbrake cable -1- into retainer on axle body -arrow-.

Handbrake cable clamping ring must lie in the middle of the clip.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Hook handbrake cable into retainers -arrows-.

– Fit handbrake cable through guide tube.
– Hook handbrake cable into compensator.

– Pretension handbrake cable with adjustment nut -arrow-.

– Fit wheels.
Tightening torque of wheel bolts ⇒ Axles, steering; Rep. gr. 44 .
– Setting the hand-brake ⇒ page 40 .
– Install centre console ⇒ Body Work; Rep. gr. 68 .

3. Handbrake 39
 Citigo 2012 ➤
Brake systems - Edition 11.2012

3.3 Setting the hand-brake

Note

♦ Resetting of the hand-brake is not required after resetting of

the rear brake due to automatic resetting of the rear wheel-
brake.
♦ Resetting is only required after replacing the hand-brake ca‐
ble, the brake carrier, the brake pads or brake shoes.

– Remove the centre console ⇒ Body Work; Rep. gr. 68 .

• Put the hand brake lever in its rest position.
– Forcefully apply the foot brake at least three times.
– Pull the handbrake on and release it three times.
This sets the components into position.
Put the hand brake lever in its rest position.
– Put the hand-brake lever into the 1st catch position (from the
rest position).
– Tighten adjusting nut -arrow- until both wheels are hard to turn
by hand.

Note

The adjusting nut -arrow- must be screwed over the end of the
tension rod (self-locking effect).

– Release hand-brake and check whether both wheels rotate

freely, if necessary release adjusting nut slightly.
– Put the hand-brake lever into the 4th catch position (after being
in the release position).
No wheel should be rotatable; tighten the adjusting nut if nec‐
essary.
– Release hand-brake and check whether both wheels rotate
freely, if necessary release adjusting nut slightly.
– Put the hand-brake lever into the 1st catch position and re‐
lease the hand-brake.
The hand-brake must automatically
Protected byreturn into
copyright. theforrelease
Copying po‐
private or commercial purposes, in part or in whole, is not permitted
sition below the 1st catch. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Install centre console ⇒ Body Work; Rep. gr. 68 .
Once reset, no resetting of the hand brake is necessary due to
automaticy adjustment of the brakes on the rear wheels.

40 Rep. gr.46 - Brakes - mechanism

 Citigo 2012 ➤
Brake systems - Edition 11.2012

4 Brake pedal
Summary of components ⇒ page 41 .
Separating the brake pedal from the brake servo unit
⇒ page 43 .
Clip the brake pedal onto the brake servo unit ⇒ page 44 .
Removing and installing brake pedal ⇒ page 44 .
Removing and installing the foot controls ⇒ page 45 .

4.1 Summary of components

Summary of components of brake pedal, LHD - left-hand drive
⇒ page 41 .
Summary of components of brake pedal, RHD - right-hand drive
⇒ page 42 .

4.1.1 Summary of components of brake ped‐

al, LHD - left-hand drive

WARNING

The travel of the brake pedal must not be shortened by addi‐

tional floor coverings.

The brake light switch is located on the master brake cylinder.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

41
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
4. Brake pedal
 Citigo 2012 ➤
Brake systems - Edition 11.2012

1 - Foot controls
❑ removing and installing
⇒ page 45
2 - Hexagon bolt
3 - Self-locking nut, 25 Nm
❑ replace after each re‐
moval
4 - Brake pedal
❑ removing and installing
⇒ page 44
5 - Cap
6 - Bearing shell
7 - Gripper
❑ for the spherical head of
the pressure rod of the
brake servo unit
8 - Self-locking nut, 25 Nm
❑ replace after each re‐
moval
9 - Bushing
10 - Bracket axle

4.1.2 Summary of components of brake ped‐

al, RHD - right-hand drive

WARNING
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
The travel of the brake pedal must not be shortened by addi‐
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
tional floor coverings. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

The brake light switch is located on the master brake cylinder.

42 Rep. gr.46 - Brakes - mechanism

 Citigo 2012 ➤
Brake systems - Edition 11.2012

1 - Cover
2 - Foot controls
❑ removing and installing
3 - Self-locking nut, 25 Nm
❑ replace after each re‐
moval
4 - Self-locking nut, 25 Nm
❑ replace after each re‐
moval
5 - Brake pedal
❑ removing and installing
⇒ page 45
6 - Cap
7 - Crash strut
8 - Screw
9 - Bearing shell
10 - Support
❑ for the spherical head of
the pressure rod of the
brake servo unit
11 - Hexagon bolt
12 - Bushing
13 - Bearing bolt

4.2 Separating the Copying

Protected by copyright. brake pedal
for private frompurposes,
or commercial the in part or in whole, is not permitted
brake withservo unit
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Special tools and workshop equipment required

♦ Release tool -T40136-

4. Brake pedal 43
 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Press the brake pedal towards the brake servo unit and hold
it in position.
1 - Brake pedal
2 - Pressure rod
3 - Retaining lugs
– Insert release tool -T40136- and pull in direction of driver seat.
When doing this, counter-hold on brake pedal. (At this stage
the brake pedal must not be allowed to move backwards.) This
causes the retaining lugs -3- of the support to be pressed off
the spherical head of the push rod -2-.
For the sake of clarity, separation of brake pedal from brake servo
is shown with pedal cluster removed.
– Pull the release tool -T40136- and brake pedal jointly towards
the driver's seat. (This causes the brake pedal to be pulled off
the spherical head of the pressure rod).

4.3 Clipping the brake pedal onto the brake

servo unit
– Hold the spherical head of the push rod in front of the support
and press the brake pedal towards the brake servo unit until
the spherical head locks audibly into place.
– Check that it is locked in place by briefly pulling on the brake
pedal.

4.4 Removing and installing brake pedal

Removing and installing the brake pedal, LHD - left-hand drive
⇒ page 44 .
Removing and installing
Protected the
by copyright. brake
Copying pedal,
for private RHD - right-hand
or commercial purposes, in partdrive
or in whole, is not permitted
⇒ page 45 unless
. authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

4.4.1 Removing and installing the brake ped‐

al, LHD - left-hand drive
Removing:
– Separating the brake pedal from the brake servo unit
⇒ page 43 .

44 Rep. gr.46 - Brakes - mechanism

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Unscrew hexagon nut -1-.

– Pull out hexagon bolt -2-.
– Remove brake pedal.
Installing:
Installation is carried out in the reverse order.
– Clip the brake pedal onto the brake servo unit ⇒ page 44 .

4.4.2 Removing and installing the brake ped‐

al, RHD - right-hand drive
Removing:
It is not possible to remove the brake pedal in the vehicle sepa‐
rately, because the hexagon bolt cannot be pulled out completely.
– Remove the foot controls ⇒ page 45 .
– Remove brake pedal.
Installing:
Installation is carried out in the reverse order.
– Clip the brake pedal onto the brake servo unit ⇒ page 44 .

4.5 Removing and installing the foot con‐

trols
Removing and installing the foot controls, LHD - left-hand drive
⇒ page 45 .
Removing and installing the foot controls, RHD - right-hand drive
⇒ page 46 .

4.5.1 Removing and installing the foot con‐

trols, LHD - left-hand drive
Removing:
– Screw out screws -1- and remove footwell trim -2-.
– Disconnect the plug from the accelerator pedal position send‐
er.
– Separating the brake pedal from the brake servo unit
⇒ page 43 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

4. Brake pedal 45
 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Remove the hexagon nuts -arrows- from the foot controls.

– Remove foot pedal cluster.
Installing:
Installation is carried out in the reverse order.
– Clip the brake pedal onto the brake servo unit ⇒ page 44 .

4.5.2 Removing and installing the foot con‐

trols, RHD - right-hand drive
Removing:
– Remove lateral dash panel cover ⇒ Body Work; Rep. gr. 70 .
– Remove lower part of the dash panel insert on the driver's side
⇒ Body Work; Rep. gr. 68 .
– Remove crash strut ⇒ Chassis; Rep. gr. 48 .
– Disconnect the plug from the accelerator pedal position send‐
er.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Separating the brake pedal from the brake servo unit
⇒ page 43 .
– Remove the hexagon nuts -arrows- from the foot controls.
– Remove foot pedal cluster.
Installing:
Installation is carried out in the reverse order.
– Clip the brake pedal onto the brake servo unit ⇒ page 44 .
Tightening torque ⇒ page 42 .

46 Rep. gr.46 - Brakes - mechanism

 Citigo 2012 ➤
Brake systems - Edition 11.2012

47 – Brakes - hydraulics
1 Front brake calipers
Assembly overview - front brake caliper ⇒ page 47
Removing and installing brake caliper piston ⇒ page 47

1.1 Assembly overview - front brake caliper

Assembly overview - brake caliper FS III:

1 - Dust cap
❑ Fit onto bleeder valve.
2 - Bleeder valve, 10 Nm
❑ apply thin coat of lithium
grease G 052 150 A2 to
thread before screwing
in
3 - Bushing
❑ insert into the brake cal‐
iper
4 - Guide bolt, 30 Nm
5 - Cover caps
❑ insert in bushing
6 - Brake caliper
7 - Sealing ring
❑ removing and installing
⇒ page 47
8 - Piston
❑ First of all apply thin coat
of lithium grease G 052
150 A2 to piston
❑ removing and installing
⇒ page 47
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
9 - Collar
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ removing and installing
⇒ page 47

1.2 Removing and installing brake caliper

piston
Special tools and workshop equipment required
♦ Piston jig -MP9-403-
♦ Disassembly wedge -3409-
♦ Lithium grease -G 052 150 A2-

1. Front brake calipers 47

 Citigo 2012 ➤
Brake systems - Edition 11.2012

Removing:
– Press piston out of brake caliper using compressed air.
Insert wooden plate in the channel so that the piston is not dam‐
aged.

– Remove sealing ring using disassembly wedge 3409.

When removing, make sure that the cylinder surface is not dam‐
aged.
Installing:
– Clean piston and gasket ring with white spirits and dry off.
– Before installing the piston and gasket ring in the brake caliper
housing thinly coat with lithium grease -G 052 150 A2- .
– Insert new gasket ring in the groove of the brake caliper.

– Position the collar with the inner sealing lip on the piston.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Insert the outer sealing lip of the collar into the groove of the
cylinder using the disassembly wedge -3409- .
To do so hold the piston with the hand.

48 Rep. gr.47 - Brakes - hydraulics

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Press the piston into the brake caliper housing using the piston
resetting jig -MP9-403 - .

Note

The inner sealing lip of the collar will clip into the piston groove.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Front brake calipers 49

 Citigo 2012 ➤
Brake systems - Edition 11.2012

2 Brake Servo Unit/Master Brake Cyl‐

inder
Assembly overview - brake servo/brake master cylinder
⇒ page 50
Removing and installing brake light switch ⇒ page 53
Removing and installing master brake cylinder ⇒ page 55
Remove and install brake servo unit ⇒ page 58

2.1 Assembly overview - brake servo/brake

master cylinder
Summary of components of brake servo unit and master brake
cylinder, LHD - left-hand drive ⇒ page 50 .
Summary of Components of brake servo unit and master brake
cylinder, RHD - right-hand drive ⇒ page 52 .

2.1.1 Summary of components of brake servo unit and master brake cylinder,
LHD - left-hand drive
The complete master brake cylinder and brake servo unit can be
replaced independently of one another.

1 - Brake fluid level warning

contact -F34-
2 - Screw cap
3 - Vacuum hose
❑ Including non-return
valve.
4 - Pressure sensor
❑ only on vehicles with
start-stop system
5 - Brake fluid reservoir
6 -Protected
Sealing plugs Copying for private or commercial purposes, in part or in whole, is not permitted
by copyright.
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
7 - Brake servo
with respect to the unit
correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

❑ On petrol engines, the

required vacuum is ob‐
tained at the intake con‐
necting piece.
❑ Functional test
– With the engine off
press down brake pedal
repeatedly with force
(this reduces the pres‐
sure already present in
the device).

– Now hold the brake ped‐

al in brake position us‐
ing a medium foot pres‐
sure and start the
engine. If the brake ser‐
vo unit operates perfect‐
ly the brake pedal must
yield noticeably under
your foot (servo boost
takes effect).

50 Rep. gr.47 - Brakes - hydraulics

 Citigo 2012 ➤
Brake systems - Edition 11.2012
❑ Renew completely in the event of a fault. Before doing so, check brake servo vacuum system
⇒ page 64 .
❑ Non-return valve (in vacuum hose) functional check ⇒ page 64 .
❑ separate from brake pedal ⇒ page 43
❑ removing and installing ⇒ page 58
8 - Gasket
❑ for brake servo unit
9 - Self-locking nut, 25 Nm
❑ replace after each removal
10 - Sealing ring
❑ replace
11 - Master brake cylinder
❑ cannot be repaired. Replace completely if a fault arises.
12 - Brake light switch -F-
❑ Including brake pedal switch -F47- .
❑ removing and installing ⇒ page 53
13 - Screw, 7 Nm
14 - Self-locking nut, 23 Nm
❑ replace after each removal
15 - Screw, 8 Nm
16 - Sealing plugs
❑ Moisten with brake fluid and press into brake master cylinder.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

2. Brake Servo Unit/Master Brake Cylinder 51

 Citigo 2012 ➤
Brake systems - Edition 11.2012

2.1.2 Summary of Components of brake servo unit and master brake cylinder,
RHD - right-hand drive
The complete master brake cylinder and brake servo unit can be
replaced independently of one another.

1 - Brake fluid level warning

contact -F34-
2 - Screw cap
3 - Brake fluid reservoir
4 - Sealing plugs
❑ moisten with brake fluid
and press into master
brake cylinder
5 - Brake servo unit
❑ on petrol engines the re‐
quired negative pres‐
sure is drawn from the
induction pipe
❑ Check for proper opera‐
tion
– With the engine off
press down brake pedal
repeatedly with force
(this reduces theProtected
pres‐ by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
sure already present in to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
with respect
the device).

– Now hold the brake ped‐

al in brake position us‐
ing a medium foot pres‐
sure and start the
engine. If the brake ser‐
vo unit operates perfect‐
ly the brake pedal must
yield noticeably under
your foot (servo boost
takes effect).
❑ Renew completely in
the event of a fault. Be‐
fore doing so, check
brake servo vacuum
system ⇒ page 64 .
❑ Non-return valve (in vacuum hose) functional check ⇒ page 64 .
❑ separate from brake pedal ⇒ page 43
❑ removing and installing ⇒ page 58
6 - Gasket
❑ for brake servo unit
7 - Self-locking nut, 25 Nm
❑ replace after each removal
8 - Sealing plugs
9 - Sealing ring
❑ replace

52 Rep. gr.47 - Brakes - hydraulics

 Citigo 2012 ➤
Brake systems - Edition 11.2012

10 - Screw, 8 Nm
11 - Master brake cylinder
❑ cannot be repaired. Replace completely if a fault arises.
12 - Vacuum hose
❑ Including non-return valve.
13 - Pressure sensor
❑ only on vehicles with start-stop system
14 - Screw, 7 Nm
15 - Brake light switch -F-
❑ Including brake pedal switch -F47- .
❑ removing and installing ⇒ page 53
16 - Self-locking nut, 23 Nm
❑ replace after each removal

2.2 Removing and installing brake light

switch
Removing and installing the brake light switch, LHD - left-hand
drive ⇒ page 53 .
Removing and installing the brake light switch, RHD - right-hand
drive ⇒ page 54 .

2.2.1 Removing and installing the brake light

switch, LHD - left-hand drive
Removing:
– Remove air filter ⇒ Engine; Rep. gr. 24 .
Vehicles with air conditioning:
– Disconnect connector -2- from high-pressure sender -G65-
-1-.
Continued for all vehicles:
– Disconnect connector -A- from brake fluid level warning con‐
tact -F34- .

– Disconnect connector -B- from brake light switch -F- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

2. Brake Servo Unit/Master Brake Cylinder 53

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Lay connectors together with wiring harness to side.

– Unscrew bolt -arrow 1- from master brake cylinder.
– Pull brake light switch -F- -2- off brake master cylinder.
Installing:
– Installation is carried out in the reverse order.
Tightening torque:
Screw to master brake cylinder 7 Nm

2.2.2 Removing and installing the brake light

switch, RHD - right-hand drive
Special tools and workshop equipment required
♦ Closing tool -T10249-
♦ Brake filling and bleeding device , e. g. -VAS 5234-
Removing:
– Remove air filter ⇒ Engine; Rep. gr. 24 .
– Place sufficient lint-free cloths in area of engine and gearbox.
– Use the brake filling and bleeding device , e.g. -VAS 5234- ,
to drain as much brake fluid as possible from the brake fluid
reservoir.
– Disconnect plug connection -A- from brake fluid level warning
contact -F34- .
– Disconnect plug -B- from the brake light switch -F- .
– Lay connectors together with wiring harness to side.
Vehicles fitted with a manual gearbox:

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Disconnect hose for master cylinder -C- from brake fluid res‐
ervoir.
– Seal hose for master cylinder -2- with sealing tool -T10249-
-1-.
Continued for all vehicles:

54 Rep. gr.47 - Brakes - hydraulics

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Unscrew fixing screw -1- for brake fluid reservoir from master
brake cylinder.
– Pull the brake fluid reservoir -2- in -direction of arrow- out of
the master brake cylinder.

– Unscrew bolt -arrow 1- from master brake cylinder.

– Pull brake light switch -F- -2- off brake master cylinder.
Installing:
– Installation is carried out in the reverse order.
– Bleeding brake system ⇒ page 72 .
Tightening torque:
Screw for brake fluid reservoir to master brake cyl‐ 8 Nm
inder Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Screw for brake
with respectlight
to the switch -F-
correctness to master
of information brake
in this cyl‐Copyright
document. 7 Nm
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
by ŠKODA AUTO A. S.�
inder

2.3 Removing and installing master brake

cylinder
Removing and installing the master brake cylinder, LHD - left-
hand drive ⇒ page 55 .
Removing and installing the master brake cylinder, RHD - right-
hand drive ⇒ page 57 .

2.3.1 Removing and installing the master

brake cylinder, LHD - left-hand drive
Special tools and workshop equipment required
♦ Closing tool -T10249-
♦ Brake filling and bleeding device , e. g. -VAS 5234-
Removing:
– On models fitted with a coded radio, pay attention to the cod‐
ing, determine if necessary.
– Remove battery ⇒ Electrical System; Rep. gr. 27 .
– Remove air filter ⇒ Engine; Rep. gr. 24 .
– Place sufficient lint-free cloths in area of engine and gearbox.
– Use the brake filling and bleeding device , e.g. -VAS 5234- ,
to drain as much brake fluid as possible from the brake fluid
reservoir.

2. Brake Servo Unit/Master Brake Cylinder 55

 Citigo 2012 ➤
Brake systems - Edition 11.2012

Vehicles with air conditioning:

– Disconnect connector -2- from high-pressure sender -G65-
-1-.
Continued for all vehicles:
– Disconnect plug connection -A- from brake fluid level warning
contact -F34- .
– Disconnect plug -B- from the brake light switch -F- .

– Then unclip wiring harness from brake master cylinder.

Vehicles fitted with a manual gearbox:

– Disconnect return hose -C- for clutch master cylinder from

brake fluid reservoir.
– Seal return hose -2- for clutch master cylinder -3- with sealing
tool -T10249- -1- or engine bung set -VAS 6122- .
– Tie return hose -2- in place above.
Continued for all vehicles:

– Unscrew fixing screw -1- for brake fluid reservoir from master
brake cylinder.
– Pull brake fluid reservoir -2- upwards -arrow- out of brake
master cylinder.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

56 Rep. gr.47 - Brakes - hydraulics

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Mark and unscrew brake lines from brake master cylinder

-1-.
– Unscrew nuts -2- from brake master cylinder.
– Carefully remove brake master cylinder from brake servo.
– Remove brake light switch -F- .
Installing:
Installation is carried out in the reverse order.
– When assembling brake master cylinder with brake servo,
make sure plunger rod and seal are properly positioned in
brake master cylinder.
– Bleeding brake system ⇒ page 72 .
Tightening torques:
Master brake cylinder to brake servo unit 23 Nm
♦ Use new nuts!

Brake lines to master brake cylinder 14 Nm

Screw for brake fluid reservoir 8 Nm
Screw for brake light switch to master brake cylinder 7 Nm

2.3.2 Removing and installing the master

brake cylinder, RHD - right-hand drive
Special tools and workshop equipment required
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ respect
with Closing tool -T10249-
to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

♦ Brake filling and bleeding device , e. g. -VAS 5234-

Removing:
– Remove air filter ⇒ Engine; Rep. gr. 24 .
– Place sufficient lint-free cloths in area of engine and gearbox.
– Use the brake filling and bleeding device , e.g. -VAS 5234- ,
to drain as much brake fluid as possible from the brake fluid
reservoir.
– Disconnect plug connection -A- from brake fluid level warning
contact -F34- .
– Disconnect plug -B- from the brake light switch -F- .
– Lay connectors together with wiring harness to side.
Vehicles fitted with a manual gearbox:

2. Brake Servo Unit/Master Brake Cylinder 57

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Disconnect hose for master cylinder -C- from brake fluid res‐
ervoir.
– Seal hose for master cylinder -2- with sealing tool -T10249-
-1-.
Continued for all vehicles:

– Unscrew fixing screw -1- for brake fluid reservoir from master
brake cylinder.
– Pull the brake fluid reservoir -2- in -direction of arrow- out of
the master brake cylinder.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Mark brake lines -1- from master brake cylinder.

– Remove brake lines -1-.
– Release the nuts -2- of the master brake cylinder.
– Carefully take the master brake cylinder out of the brake servo
unit.
– Remove brake light switch -F- .
Installing:
Installation is carried out in the reverse order.
– When assembling brake master cylinder with brake servo,
make sure plunger rod and seal are properly positioned in
brake master cylinder.
– Bleeding brake system ⇒ page 72 .
Tightening torques:
Master brake cylinder to brake servo unit 23 Nm
♦ Use new nuts!

Brake lines to master brake cylinder 14 Nm

Screw for brake fluid reservoir 8 Nm
Screw for brake light switch to master brake cylinder 7 Nm

2.4 Removing and installing brake servo

unit
Removing and installing the brake servo unit, LHD - left-hand
drive ⇒ page 59 .
Removing and installing the brake servo unit, RHD - right-hand
drive ⇒ page 61 .

58 Rep. gr.47 - Brakes - hydraulics

 Citigo 2012 ➤
Brake systems - Edition 11.2012

2.4.1 Removing and installing the brake servo

unit, LHD - left-hand drive
Special tools and workshop equipment required
♦ Closing tool -T10249-
♦ Brake filling and bleeding device , e. g. -VAS 5234-
Removing:
– On models fitted with a coded radio, determine the coding.
– Remove battery ⇒ Electrical System; Rep. gr. 27 .
– Unscrew the engine control unit from the bracket and lay to
the side ⇒ Engine; Rep. gr. 24 .
– Remove battery tray ⇒ Electrical System; Rep. gr. 27 .
– Remove air filter ⇒ Engine; Rep. gr. 24 .
– Place sufficient lint-free cloths in area of engine and gearbox.
– Use the brake filling and bleeding device , e.g. -VAS 5234- ,
to drain as much brake fluid as possible from the brake fluid
reservoir.
Vehicles with air conditioning:
– Disconnect connector -2- from high-pressure sender -G65-
-1-.
Continued for all vehicles:

– Disconnect plug connection -A- from brake fluid level warning

contact -F34- .
– Disconnect plug -B- from the brake light switch -F- .
– unless
Unclip wiring harness
AUTO from brake master cylinder.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
authorised by ŠKODA A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Vehicles fitted with a manual gearbox:
– Disconnect return hose -C- for clutch master cylinder from
brake fluid reservoir.

2. Brake Servo Unit/Master Brake Cylinder 59

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Seal return hose -2- for clutch master cylinder -3- with sealing
tool -T10249- -1- or engine bung set -VAS 6122- .
– Tie return hose -2- in place above.
Continued for all vehicles:
– Pull vacuum hose out of brake servo.

– Mark and unscrew brake lines -A and B- from brake master

cylinder and immediately seal brake lines with sealing plugs
from repair kit part number 1H0 698 311 A.
– Slightly loosen brake lines -A and B- from hydraulic unit and
lay to one side.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Screw out screws -1- and remove the cover -2-.
– Separating the brake pedal from the brake servo unit
⇒ page 43 .

60 Rep. gr.47 - Brakes - hydraulics

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Remove hexagon nuts -arrows-.

– Carefully remove the brake servo unit from the vehicle.
If brake servo sticks in holes, loosen both remaining nuts on
mounting bracket.
– Unscrew brake master cylinder from brake servo.
– Carefully remove brake master cylinder from brake servo.
Installing:
– Installation is carried out in the reverse order.
Observe following points when installing:
– Clip the brake pedal onto the brake servo unit ⇒ page 44 .
– Bleeding brake system ⇒ page 72 .
Tightening torques:
Brake servo to pedal cluster/bulkhead 25 Nm
♦ Use new nuts!

Master brake cylinder to brake servo unit 23 Nm

♦ Use new nuts!

Screw for brake fluid reservoir 8 Nm

Screw for brake light switch to master brake cylinder 7 Nm
Brake lines to master brake cylinder 14 Nm

2.4.2 Removing and installing the brake servo

unit, RHD - right-hand drive
Special tools and workshop equipment required
♦ Closing tool -T10249-
♦ Brake filling and bleeding device , e. g. -VAS 5234-
Removing:
– Remove air filter ⇒ Engine; Rep. gr. 24 .
– Remove the cooling water tank cover ⇒ Body Work; Rep. gr.
50 .
– Remove bulkhead plenum chamber ⇒ Body Work; Rep. gr.
50 .
– Unclip fuel feed line -1- and vent line -2- from the line holder
-3-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

2. Brake Servo Unit/Master Brake Cylinder 61

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Open clamps -arrows-.

– Unscrew securing bolt -1- and remove toothed belt guard -2-.
– Place sufficient lint-free cloths in area of engine and gearbox.
– Use the brake filling and bleeding device , e.g. -VAS 5234- ,
to drain as much brake fluid as possible from the brake fluid
reservoir.

– Disconnect plug connection -A- from brake fluid level warning

contact -F34- .
– Disconnect plug -B- from the brake light switch -F- .
Vehicles fitted with a manual gearbox:
– Disconnect return hose -C- for clutch master cylinder from
brake fluid reservoir.

– Seal return hose -2- for clutch master cylinder -3- with sealing
tool -T10249- -1- or engine bung set -VAS 6122- .
– Tie return hose -2- in place above.
Continued for all vehicles:
– Pull vacuum hose out of brake servo.

– Unscrew fixing screw -1- for brake fluid reservoir from master
brake cylinder.
– Pull the brake fluid reservoir -2- in -direction of arrow- out of
the master brake cylinder.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

62 Rep. gr.47 - Brakes - hydraulics

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Mark brake lines -1- from master brake cylinder.

– Remove brake lines -1-.
– Release the nuts -2- of the master brake cylinder.
– Carefully take the master brake cylinder out of the brake servo
unit.
– Separating the brake pedal from the brake servo unit
⇒ page 43 .
– Remove lower part of the dash panel insert on the driver's side
⇒ Body Work; Rep. gr. 68 .

– Unscrew the nuts -arrows-.

– Remove fixing screws for pendulum support from gearbox ⇒
Engine; Rep. gr. 10 .

– Swivel the brake servo unit -1- in direction of arrow and care‐
fully take it out of the vehicle.

Note

♦ If brake servo sticks in holes, loosen both remaining nuts on

mounting bracket.
♦ In order to facilitate the removal of the brake servo unit, tilt the
engine to the front.

Installing:
– Installation is carried out in the reverse order.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Observe following points when installing:
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Clip the brake pedal onto the brake servo unit ⇒ page 44 .
– Bleeding brake system ⇒ page 72 .
Tightening torques:
Brake servo to pedal cluster/bulkhead 25 Nm
♦ Use new nuts!

Master brake cylinder to brake servo unit 23 Nm

♦ Use new nuts!

Screw for brake fluid reservoir 8 Nm

Screw for brake light switch to master brake cylinder 7 Nm
Brake lines to master brake cylinder 14 Nm

2. Brake Servo Unit/Master Brake Cylinder 63

 Citigo 2012 ➤
Brake systems - Edition 11.2012

3 Vacuum system
Checking the non-return valve ⇒ page 64
Checking vacuum system ⇒ page 64

3.1 Checking the non-return valve

♦ Air must pass through non-return valve -A- in direction of ar‐
row.
♦ The non-return valve must be closed to the passage of air in
the reverse direction.
Pay attention to correct installation position!

3.2 Checking vacuum system

The following instructions are intended to help you find the causes
of problems effectively and objectively in the event of complaints
about the brake servo or in the event of a so-called »hard brake
pedal«.
This check relates to the following components:
♦ Brake servo unit
♦ Oil seal between brake master cylinder and brake servo.
♦ Non-return valve
♦ Vacuum hoses with connectors
♦ Vacuum pump (if included)
The measuring results will be influenced by the geographical lo‐
cation. The higher the location is above sea level, the lower the
air pressure will be.
Take note of the following test requirements:
♦ Visual inspection of all vacuum hoses for damage (e.g. cracks
or marten bite) and to check that they are correctly and firmly
attached
♦ Ensure cleanliness when working on vacuum system.
♦ Before starting work, clean engine compartment if necessary.
Special tools and workshop equipment required
♦ Vacuum gauge for brake servo -VAS 6721-

3.2.1 Connecting vacuum gauge for brake

servo -VAS 6721-
– Pull vacuum hose out of brake servo.
First press the brake pedal several times in order to facilitate re‐
moval of the vacuum hose.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

64 Rep. gr.47 - Brakes - hydraulics

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Place brake servo vacuum gauge -VAS 6721- between them

-see following illustrations-.
Item Com‐ Explanation
num‐ po‐
ber nent
A Cut- In direction of vacuum hose, non-return valve and,
off if included, vacuum pump
valve
B Cut- ♦ Open to facilitate removal of brake servo vac‐
off uum gauge -VAS 6721-
valve
♦ Open to simulate a fault source
♦ Connection of manual vacuum pump -VAS
6213-

C Cut- In direction of brake servo

off
valve

– Push hose -A- of brake servo vacuum gauge -VAS 6721- onto
vacuum hose and press adapter -C- into brake servo.

3.2.2 Checking vacuum generation

Note

♦ The average air pressure of the earth's atmosphere at sea

level is 1013 mbar and decreases steeply as the altitude in‐
creases (approx. 100 mbar/1,000 m altitude). Local and time
fluctuations also influence vacuum generation.
♦ A cold engine, a switched-on air-conditioning system as well
as engine idling have an adverse influence on generation of a
vacuum.

– Before starting work, check all vacuum hoses for damage (e.g.
cracks or marten bite) and to check that they are correctly and
firmly attached
– Connect brake servo vacuum gauge -VAS 6721- ⇒ page 64 .

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

3. Vacuum system 65
 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Open cut-off valve -A-.

– Close cut-off valves -B+C-.
– Start warm engine (> 60°C), press accelerator briefly (engine
speed greater than 2000/min).
– Read indicated measured value.
Normally (see notes), the vacuum that is generated should be
between 600 and 950 mbar (depending on engine size).
If the measured value is not reached even through the precondi‐
tions (see notes) have been met, the vacuum system must first
be checked for leaks.
– For comparison purposes, generate the vacuum with the man‐
ual vacuum pump -VAS 6213- ⇒ page 67 .
Open cut-off valve -B- to facilitate removal of hose connections
and adapter.

3.2.3 Checking for leaks

Note

♦ The average air pressure of the earth's atmosphere at sea

level is 1013 mbar and decreases steeply as the altitude in‐
creases (approx. 100 mbar/1,000 m altitude). Local and time
fluctuations also influence vacuum generation.
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ A cold engine, a switched-on air-conditioning system
with respect to the as well of information in this document. Copyright by ŠKODA AUTO A. S.�
correctness
as engine idling have an adverse influence on generation of a
vacuum.

– Before starting work, check all vacuum hoses for damage (e.g.
cracks or marten bite) and to check that they are correctly and
firmly attached
– Connect brake servo vacuum gauge -VAS 6721- ⇒ page 64 .
– Open cut-off valve -A-.
– Close cut-off valves -B+C-.
– Start warm engine (> 60°C), press accelerator briefly (engine
speed greater than 2000/min).
Normally (see notes), the vacuum that is generated should be
between 600 and 950 mbar (depending on engine size).

66 Rep. gr.47 - Brakes - hydraulics

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Open cut-off valve -C- to evacuate brake servo.

– Switch off engine.
– Read and make a note of measured value shown.
A vacuum decrease of 400 mbar in 12 hours is permissible.
If the vacuum decrease is greater, then check for leaks in the
vicinity of ...
1- Brake servo unit
or
2- Non-return valve, vacuum hoses with connectors and vac‐
uum pump/intake manifold.

If there are large leaks, the vacuum decreases steeply within a

few seconds.
Vacuum check in vicinity of brake servo:

– After generation of vacuum, close cut-off valve -A- in order to

check brake servo vacuum system.
Vacuum check in vicinity of non-return valve, vacuum hoses with
connectors and vacuum pump/intake manifold:

– Once vacuum pressure has been generated, close shut-off

valve -C- in order to check vacuum system using brake servo
vacuum gauge -VAS 6721- up to intake manifold or vacuum
pump.
Open cut-off valve -B- to facilitate removal of hose connections
and adapter.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

3.2.4 Vacuum generation with manual vac‐

uum pump -VAS 6213-
Instead of vacuum generation by means of engine or vacuum
pump, the vacuum can be generated with the manual vacuum
pump -VAS 6213- in certain cases.
– To do this, connect manual vacuum pump -VAS 6213- to vac‐
uum hose from connection -B- on brake servo vacuum gauge
-VAS 6721- .
– Open cut-off valve -B-.
– Generate vacuum with hand vacuum pump -VAS 6213- until
between 600 and 950 mbar is shown on brake servo vacuum
gauge -VAS 6721- .
– Then, carry out the corresponding checks.

3. Vacuum system 67
 Citigo 2012 ➤
Brake systems - Edition 11.2012

4 Brake lines
Repairing brake lines ⇒ page 68

4.1 Repairing brake lines

Using the brake line flaring tool -VAS 6056- , the brake lines can
be crimped with a pipe outside diameter of 5 mm, without dam‐
aging the coating. So that in certain cases parts of the brake lines
can be replaced cheaply.
The use of flanging tool V.A.G. 1356 is not permitted due to the
coating and the diameter of the black brake lines.

Note

♦ Brake lines may only be bent to max. 90°, as they otherwise

kink or display deformations which constrict the cross-section
of the line to an impermissible degree.
♦ Preferably separate brake lines at underbody.
♦ The positions of the intermediate pieces must be selected so
that they cannot chafe on moving parts.
♦ Do not grease spindle, clean only with methylated spirits.

Special tools and workshop equipment required

♦ Brake line flaring tool -VAS 6056-
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♦ Brake unless
fillingauthorised
and bleeding equipment
by ŠKODA AUTO , e.AUTO
A. S. ŠKODA g. -VAS 5234-
A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
List of individual tools:
Pos. Tool Tool number
1 Flanging tool (incl. flanging jaws VAS 6056/1
VAS 6056/6)
2 Pipe cutter VAS 6056/2
3 Brake line scraper1) VAS 6056/3
4 Gripping pliers with plastic VAS 6056/4
chuck jaws
5 Tube bending tool VAS 6056/5
6 Offset screwdriver SW6 -
7 Flaring chucks VAS 6056/7
1) The grub screws (in the shank and sideways) are adjusted and must not be
altered!

4.1.1 Flaring tool - summary of components

68 Rep. gr.47 - Brakes - hydraulics

 Citigo 2012 ➤
Brake systems - Edition 11.2012

1 - Flaring tool top part

❑ Unscrew to change
flanging jaws.
2 - Attachment for door handle
❑ Must be unscrewed to
access securing bolt for
upper part.
3 - Fixing screw
❑ for flaring tool top part
4 - Center the grub screws for
flaring chucks
❑ and hold the flaring
chucks
❑ 2 mm hexagon socket
5 - Flaring chucks
❑ different
❑ Mounting instruction
⇒ page 69

Mounting instruction of flaring chucks:

♦ VAS 6056/6 (dark) for black brake lines
♦ VAS 6056/7 (bright) for green brake lines

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
The arrow, on the rounded side of the flaring chucks, must point
to the housing edge and the straight side of the flaring chucks
must be installed to the spindle, otherwise the flaring head is not
properly formed.

4.1.2 Work instruction

– Unscrew the affected brake line on the brake caliper or wheel-
brake cylinder, while doing so collect escaping brake fluid and
dispose according to the specifications.

4. Brake lines 69
 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Cut through the brake line in a suitable location (straight, freely

accessible piece) with the pipe cutter -2-.
– Remove the removable part.
– Degrease the surface of the brake line.

– Clamp the brake line in the gripping pliers -4- tight enough, so
that it protrudes approx. 50 mm out of the plastic chuck jaws.
– Tension the peeler -3- in a boring machine and place it onto
the brake line.
– Clean the brake line using the slower speed of the boring ma‐
chine and by exerting a slight pressure (peel off the coating of
the brake line).
The length of the peeling is determined by the stop in the peeler.
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– Separate theauthorised
unless peelerbyfrom
ŠKODAthe brake
AUTO line and
A. S. ŠKODA AUTOremove peel
A. S. does not res‐ or accept any liability
guarantee
idues. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Remove the gripping pliers and push the pipe screw -D- onto
the brake line.

– Push the brake line -B- against the stop -A- in the flaring tool.

Note

When tightening the Allen screws the brake line must lie against
the stop, otherwise the flaring head does not function properly.

– Pre-tension the brake line in the flaring tool so that the brake
line can no longer be moved. Fold up the stop -A- and then
tighten the Allen screws crosswise with the offset screwdriver
-C-.

70 Rep. gr.47 - Brakes - hydraulics

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Turn the spindle in the flaring tool up to the stop.

– Turn back the spindle once again.
– Loosen the Allan screws crosswise.
– Take the brake line out of the flaring tool, clean and check the
brake line as well as the flaring head.
Briefly rinse the part of the brake line remaining in the the vehicle:
– Connect the brake filling and bleeding device , e.g. -VAS
5234- , fit the hose of the bleeding bottle onto the flaring head
of the brake line and allow the brake filling and bleeding device
e.g. -VAS 5234- to run briefly until some brake fluid has passed
through.
– Blow through the newly inserted brake line with compressed
air.

– Assemble the brake lines together with the connecting piece

-E-.
– Mount brake line.
– Bleeding brake system ⇒ page 72 .

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

4. Brake lines 71
 Citigo 2012 ➤
Brake systems - Edition 11.2012

5 Hydraulic system
General notes on brake fluid ⇒ page 72
Bleeding the brake system with the brake filling and bleeding de‐
vice ⇒ page 72
Bleeding the brake system without using the brake filling and
bleeding device ⇒ page 73
Checking the master brake cylinder for tightness ⇒ page 74
Testing wheel-brake cylinder for tightness ⇒ page 75

5.1 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.
♦ Brake fluid is hygroscopic, i.e. it retains humidity from the am‐
bient air, and must therefore always be stored in airtight con‐
tainers.
♦ Rinse any brake fluid spills with a lot of water.

5.1.1 Change brake fluid

Maintenance and repair, to be precise ⇒ Maintenance ; Booklet
Citigo

5.2 Bleeding the brake system of air with the

brake filling and bleeding device
Special tools and workshop equipment required
♦ Brake filling and bleeding device. -VAS 5234-
♦ Bleeding bottle (commercially available)
♦ Tool set for brake bleeding -VAS 6564-
A pre-pressure of 2 bar is required for bleeding the hydraulic unit.
– Unscrew cap from the brake fluid reservoir.
– Connect the thread plug of the brake filling and bleeding de‐
vice . -VAS 5234- or -V.A.G 1869- to the brake fluid reservoir.
– Remove the dust caps of the bleeder valves at the brake cal‐
ipers.
– Switch on the brake filling and bleeding device and activate
the system with a brake fluid pressure of approx. 0.2 MPa.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

72 Rep. gr.47 - Brakes - hydraulics

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Fit the hose of the bleeding bottle -1- onto the corresponding
bleeder valve.
– Loosen bleeder valve.

Note

Slacken the vent valve using the set of tools for brake bleeding -
VAS 6564- and tighten.

– Extract as much brake fluid as possible until even the smallest

air bubbles have escaped.
– Close vent valve.
– Repeat this procedure for all brake calipers in the prescribed
sequence until the brake system is fully bled.
Bleeding sequence:
1- Rear right wheel-brake cylinder
2- Rear left wheel-brake cylinder
3- Front right brake caliper
4- Front left brake caliper
– Inspect pedal position and idle travel at brake pedal. Idle trav‐
el: max. 1/3 of pedal travel.
– Repeat the whole procedure if necessary (several times), until
perfect bleeding is achieved.
– Disconnect the brake filling and bleeding device .
– Disconnect the brake filling and bleeding device from the
brake fluid reservoir.
– Fit dust caps onto bleeder valves.
– If necessary, correct the brake fluid level in the brake fluid res‐
ervoir.
After bleeding, perform a test drive. While doing so perform at
least one ABS adjustment!

5.3 Bleeding the brake system of air without

using the brake filling and bleeding de‐
vice
Special tools and workshop equipment required
♦ Bleeding bottle (commercially available)
♦ Tool set for brake bleeding -VAS 6564-
♦ Brake fluid ⇒ page 72
Carry out subsequent bleeding when:
♦ brake pedal travel is too long or so-called »soft brake pedal«
Subsequent bleeding requires the assistance of a second me‐
chanic.
– Hook in the catch pan on the vehicle.
– Remove dust cap of bleeder valve on brake caliper.

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with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

5. Hydraulic system 73
 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Fit the hose of the bleeding bottle -1- onto the corresponding
bleeder valve.
– Press brake pedal and then loosen the bleeder valve.

Note

Slacken the vent valve using the set of tools for brake bleeding -
VAS 6564- and tighten.

– Tighten the vent valve with the brake pedal pressed down.
– Release brake pedal.
– Repeat this procedure until even the smallest air bubbles have
escaped from the system.
– Repeat this procedure for all brake calipers in the prescribed
sequence until the brake system is fully bled.
This bleed sequence must be carried out 5 times per brake cali‐
per.
Bleeding sequence:
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1- Rear right wheel-brake cylinder unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
2- Rear left wheel-brake cylinder
3- Front right brake caliper
4- Front left brake caliper
– Inspect pedal position and idle travel at brake pedal. Idle trav‐
el: max. 1/3 of pedal travel.
– Repeat the whole procedure if necessary (several times), until
perfect bleeding is achieved.
– Fit dust caps onto bleeder valves.
– If necessary, correct the brake fluid level in the brake fluid res‐
ervoir.
After bleeding, perform a test drive. While doing so perform at
least one ABS adjustment!

5.4 Checking the master brake cylinder for

tightness
Special tools and workshop equipment required
♦ Tester for brake pressure regulator -V.A.G 1310 A-
♦ Adapter M10 -V.A.G 1310/6-
Inspection requirement:
Brake system ( ABS hydraulic unit -N55- , brake hoses, brake
lines and brake calipers) is working properly and is not leaking.
Carry out the following tasks:
– Release the vent valve on one of the front brake calipers.

74 Rep. gr.47 - Brakes - hydraulics

 Citigo 2012 ➤
Brake systems - Edition 11.2012

– Connect the pressure gauge of the tester -V.A.G 1310 A- and

bleed.
– Push down brake pedal until the pressure gauge on the tester
indicates 5 MPa (50 bar).
– Throughout the test which lasts 45 s the pressure loss must
not exceed 0.4 MPa (4 bar).
– If the pressure loss exceeds 0,4 MPa (4 bar) replace the mas‐
ter brake cylinder.

Tightening torque:
Vent valve in brake caliper 10 Nm

5.5 Testing wheel-brake cylinder for tight‐

ness

Note

♦ The tightness test is performed only visually without using any

tools and without removing the dust cap.
♦ The dust cap may get damaged in case of removal.
♦ Slight traces of grease in the area of the wheel-brake cylinder
do not point to a leakage. It is essentially assembly grease.

– Check the wheel-brake cylinder.

– If brake fluid drips out of the wheel-brake cylinder, the wheel-
brake cylinder must be replaced.

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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

5. Hydraulic system 75