Service

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Touareg 2003 ➤
Brake systems

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Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

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

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Technical information should always be available to the foremen and mechanics, because their
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 Volkswagen AG, Wolfsburg K0058961020

 Touareg 2003 ➤
Brake systems - Edition 07.2009

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Brake allocation via PR No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Example of a vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Rear brakes (disc brakes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Brake master cylinder and brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A. G. ..V.o.lk.sw. a. g.e.n . . . . . . . . . . . . . . . . . . 8
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45 - Anti-lock brake system . . . . . . . . . . . . . .ed.b.y . . . . . . . . . . . . . . . . . . . . .t g.ua.ra. . . . . . . 9
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1 General notes for anti-lock brake systemut (ABS) . . . . . . .
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2 Notes for repair work on the ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3 Connecting VAS 5051 and selecting functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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4 Electrical/electronic components and fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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5 Fault display via warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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6 Assembly overview - hydraulic unit, brake servo/brake master cylinder . . . . . . . . . . . . . . 18

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6.1 ABS MK 25 to week 48/06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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6.2 ABS MK 25 E1 from week 48/06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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7 Removing and installing parts of ABS system on front and rear axle . . . . . . . . . . . . . . . . 31
7.1 Removing and installing speed sensor on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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7.2 Removing and installing parts of ABS system on rear axle . . . . . . . . . . . . . . . . . . . . . . . . 32
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7.3 Removing and installing speed sensor on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

8 Removing and installing parts of ESP system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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8.1 Removing and installing ESP sensor unit G419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

8.2 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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1 Repairing front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . do 36

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1.1 Repairing front brakes, FN 3 brake caliper (16") . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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1.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

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1.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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1.4 Repairing front brake, Brembo 17" brake caliper (1LC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
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1.5 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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1.6 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.7 Repairing front brake, Brembo 17" brake caliper (1LE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.8 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.9 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.10 Repairing front brake, Brembo 18" brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
1.11 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.12 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
1.13 Repairing front brake, Brembo 18" brake caliper Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
1.14 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
1.15 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2 Repairing rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.1 Repairing rear brakes, brake caliper FN 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Contents i
 Touareg 2003 ➤
Brake systems - Edition 07.2009

2.4 Removing and installing brake shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

2.5 Repairing rear brakes, Brembo 17" brake caliper (1KF) . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.6 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.7 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.8 Removing and installing brake shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.9 Repairing rear brakes, Brembo 17" brake caliper (1KQ) . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.10 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.11 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.12 Removing and installing brake shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
2.13 Repairing rear brakes, 18" brake caliper Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.14 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.15 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.16 Removing and installing brake shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.17 Adjusting parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3 Assembly overview - foot-operated parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.1 Parking brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.2 Transfer module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.3 Rear brake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.4 Removing and installing parking brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
4 Brake cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .w.a.ge. n. A. G. ..V.ol.ks. w. a.g.en. A. G. .do.e.s . . . . . . . . . . 107
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4.1 Removing and installing rear brake cables . . . b. y.V.o . . . . . . . . . . . . . . . . . . . . . .ot.g.ua. . . . . . 107
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4.2 Removing and installing front brake cable h.or.is. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .nt.ee. . . 108
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5 Assembly overview - brake pedal (LHD)ss a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a.c 110
5.1 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

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5.2 Removing and installing brake light switch F and brake pedal switch F47 . . . . . . . . . . . . 112
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47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

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1 Repairing front brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

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1.1 Repairing FN 3 brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

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1.2 Removing and installing piston for brake caliper FN 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

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1.3 Repairing Brembo brake calipers (17", 18" and 18" Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . 117
1.4 Removing and installing Brembo brake caliper piston (17", 18" and 18" Plus) . . . . . . . . . . 120

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2 Repairing rear brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
2.1 Repairing FN 44 brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

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2.2 Removing and installing piston for FN 44 brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

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2.3 Repairing Brembo brake calipers (17"and 18" Plus) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
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2.4 Removing and installing rear brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
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3 Pressurised leak test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

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4 Bleeding brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

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4.1 Bleeding brake system with brake filling and bleeding unit VAS 5234 or brake filling and
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bleeding unit V.A.G 1869 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

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4.2 Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

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5 Assembly overview - brake servo/brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 136
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5.1 Removing and installing diaphragm movement potentiometer in brake servo G420 . . . . 137
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5.2 Removing and installing brake pressure sender G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
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6 Brake servo vacuum supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

6.1 Overview - vacuum pump for brake servo (diesel vehicles) . . . . . . . . . . . . . . . . . . . . . . . . 139
6.2 Assembly overview - vacuum pump for brakes V192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.3 Checking non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
7 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
7.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
7.2 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
8 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
8.1 Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

ii Contents
 Touareg 2003 ➤
Brake systems - Edition 07.2009
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9.2 Work instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

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Contents iii
 Touareg 2003 ➤
Brake systems - Edition 07.2009

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Contents
 Touareg 2003 ➤
Brake systems - Edition 07.2009

00 – Technical data
1 Brake
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♦ Arrow 1 - Rear brakes -1KF

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♦ Arrow 2 - Front brakes -1LC

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The following table explains the PR numbers. These are impor‐

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Engine PR No. Front brake

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2.5 l - 120, 128 kW TDI 1LB FN 3 (16”)

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3.0l - 155, 165, 176kW 1LC / 1LE Brembo (17")

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4.2 l - 228 kW Prote AG.

4.2 l -257 kW 1LF Brembo (18")

5.0 l - 230, 258 kW TDI
6.0 l - 331 kW
5.0 l - 258 kW TDI 1LT / 1LU 1) Brembo (18" Plus)
6.0 l - 331 kW
1) 1LT from week 22/2008; 1LU from week 08/2007
Country-specific brake for North America:
Engine PR No. Front brake
4.2 l - 257 kW 1LE Brembo (17")
3.0 l - 165 kW TDI 1LA Brembo (17")

1.3 Rear brakes (disc brakes)

Engine PR No. Rear brakes
2.5 l - 120, 128 kW TDI 1KE FN 44 (16”)
3.0l - 155, 165, 176 kW 1KF / 1KQ Brembo (17")
TDI
3.2 l - 162, 177 kW
3.6 l - 206 kW
4.2 l - 228 kW
4.2 l - 257 kW
5.0 l - 230, 258 kW TDI

1. Brake allocation via PR No. 1

 Touareg 2003 ➤
Brake systems - Edition 07.2009

6.0 l - 331 kW
5.0 l - 258 kW TDI 1KD / 2ED 1) Brembo (18" Plus)
6.0 l - 331 kW
1) 1KD from week 22/2008; 2ED from week 08/2007
Country-specific brake for North America:
Engine PR No. Front brakes
3.0l - 165 kW TDI 2EE Brembo (17") n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
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a ac
ss

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nl

pt
du

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itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

2 Rep. Gr.00 - Technical data

 Touareg 2003 ➤
Brake systems - Edition 07.2009

2 Technical data

2.1 Brake master cylinder and brake servo

Brake master cylinder ∅ in mm 26.99
Brake servo ∅ in inch 9"/10" tandem

2.2 Front brakes

2.2.1 Front brakes, FN 3 (16")
Item PR No. 1LB
1 Brake caliper FN 3 (16”) n AG. Volkswagen AG do
lkswage es n
2 Brake pad, mm 12.5 d by Vo ot g
ua
thickness ris
e ran
tee
tho or
Brake pad, wear mm a 2
u ac
ss
limit without

ce
le

back plate
un

pt
an
d
itte

y li
3 Brake disc ∅ in mm 308
rm

ab
pe

ility
Brake disc, mm 29.5
ot

wit
thickness
, is n

h re
Brake disc, mm 25.5
hole

spec
wear limit
es, in part or in w

t to the co
4 Brake caliper ∅ in mm 60
piston

rrectness of i
l purpos

2.2.2 Front brake, Brembo (17")

PR No.: 1LC

nform
mercia

Item PR No. 1LC

a
com

tion in
1 Brake caliper Brembo (17")
r
te o

thi
2 Brake pad, mm 10 s
iva

do
r

thickness
rp

cum
fo

en
g

Brake pad, wear mm 2

n

t.
yi Co
op
limit without C py
t. rig
back plate gh ht
pyri by
Vo
co
3 Brake disc ∅ in mm 330
by lksw
cted agen
Prote AG.
Brake disc, mm 32
thickness
Brake disc, mm 30
wear limit
4 Brake caliper ∅ in mm 2 x 34
piston 2 x 36
2 x 38

2. Technical data 3
 Touareg 2003 ➤
Brake systems - Edition 07.2009

PR No.: 1LE
Item PR No. 1LE / 1LA
1 Brake caliper Brembo (17")
2 Brake pad, mm AG. Volks11
wagen AG
agen does
thickness Volksw not
by gu
ara
Brake pad, wear rise mm
d 2 nte
limit without utho eo
ra
back plate ss a c

ce
le

3 Brake disc ∅ in mm 330

un

pt
an
d
itte

Brake disc, mm 32

y li
erm

ab
thickness

ility
ot p

Brake disc, mm 30

wit
is n

wear limit

h re
ole,

spec
4 Brake caliper ∅ in mm 4 x 46
urposes, in part or in wh

piston

t to the co
rrectne
2.2.3 Front brake, Brembo (18")

ss o
Item PR No. 1LF
cial p

f inform
1 Brake caliper Brembo (18")
mer

atio
2 Brake pad, mm 10
om

thickness
n
c

i
or

n thi
e

Brake pad, wear mm 2

t

sd
va

limit without
i

o
pr

cum
r

back plate
fo

en
ng

t.
yi
3 Brake disc ∅ in mm 350
Co
Cop py
t. rig
Brake disc, mm 34
gh ht
yri by
thickness
cop Vo
by lksw
cted agen
Prote
Brake disc, mm 32
AG.

wear limit
4 Brake caliper ∅ in mm 2 x 30
piston 2 x 34
2 x 38

2.2.4 Front brake, Brembo (18" Plus)

Item PR No. 1LT / 1LU
1 Brake caliper Brembo (18" Plus)
2 Brake pad, mm 10
thickness
Brake pad, wear mm 2
limit without
back plate
3 Brake disc ∅ in mm 368
Brake disc, mm 36
thickness
Brake disc, mm 34
wear limit
4 Brake caliper ∅ in mm 6 x 36
piston

4 Rep. Gr.00 - Technical data

 Touareg 2003 ➤
Brake systems - Edition 07.2009

2.3 Rear brakes

2.3.1 Rear brakes (16" brake disc)
Item PR No. 1KE
1 Brake caliper FN 44 (16”)
2 Brake pad, mm 13
thickness
Brake pad, wear mm 2
limit without
back plate
3 Brake disc ∅ in mm 314
Brake disc, mm 22
thickness
Brake disc, mm 18
wear limit
4 Brake caliper ∅ in mm 44
piston

2.3.2 Rear brakes (17" brake disc)

PR No.: 1KF
Item PR No. 1KF / 2EE
1 Brake caliper Brembo (17")
2 Brake pad, mm 11
thickness
Brake pad, wear mm
AG. Volkswagen AG 2
agen does
limit withouto lksw not
back eplateyV gu
db ara
ris nte
3 aBrake
ut
ho
disc ∅ in mm 330 eo
ra
s
s Brake disc, c
mm 28
ce
le

thickness
un

pt
an
d
itte

Brake disc, mm 26
y li
erm

ab

wear limit
ility
ot p

4 Brake caliper ∅ in mm 2 x 28
wit
is n

h re

piston 2 x 30
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

2. Technical data 5
 Touareg 2003 ➤
Brake systems - Edition 07.2009

PR No.: 1KQ
Item PR No. 1KQ
1 Brake caliper Brembo (17")
2 Brake pad, mm 11
thickness
Brake pad, wear mm 2
limit without
back plate
3 Brake disc ∅ in mm 330
Brake disc, mm 28
thickness
Brake disc, mm 26
wear limit AG. Volkswagen AG d
sw agen oes
olk not
V
4 Brake caliper ∅ in mm d by 2 x 44 gu
ara
piston rise nte
ho eo
ut r a ac
ss

ce
le
un

pt
an
d
itte

2.3.3 Rear brakes (18" Plus brake disc)

y li
erm

ab
ility
ot p

Item PR No. 1KD / 2ED

wit
is n

h re
1 Brake caliper Brembo (18" Plus)
ole,

spec
urposes, in part or in wh

2 Brake pad, mm 11

t to the co
thickness
Brake pad, wear mm 2
limit without

rrectne
back plate
3 Brake disc ∅ in mm 358

ss o
Brake disc, mm 28
cial p

thickness f inform
mer

Brake disc, mm 26
atio
m

wear limit
o

n
c

i
or

4 Brake caliper ∅ in mm 4 x 30
thi
te

sd
a

piston
iv

o
pr

cum
r
fo

en
ng

t.
yi Co
op py
2.3.4 Parking brake (16" brake drum)
t. C rig
gh ht
pyri by
Vo
co lksw
by
Item cted agen
Prote AG.

1 Brake drum ∅ in 185

mm
2 Brake lining, mm 30
width
Brake lining, mm 5.5
total thickness

6 Rep. Gr.00 - Technical data

 Touareg 2003 ➤
Brake systems - Edition 07.2009

2.3.5 Parking brake (17" brake drum)

Item
1 Brake drum ∅ in 210
AG. Vmm
olkswagen AG
agen does
lksw not
2 Brake d bylining,
Vo
mm g30
ua
ran
width
orise
tee
th or
ss
au
Brake lining, mm 5.5 ac
total thickness

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

2. Technical data 7
 Touareg 2003 ➤
Brake systems - Edition 07.2009

3 Brake test

3.1 General
♦ The drive is provided by the roller dynamometer.
♦ For the test, ensure for vehicles with a manual gearbox that
the gear lever is in neutral and for vehicles with an automatic
gearbox, that the selector lever is in “N”.
♦ For the test, observe the specifications provided by the man‐
ufacturer of the roller dynamometer.

Note

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

3.2 Test
The brake test must be performed on a regulated contra-rotating
roller brake test stand.
Contra-rotating means that the dynamometer rollers are driven
forwards on one side and backwards on the opposite side.
Regulated means that the speed of the brake test stand rollers is
so controlled so that there is no difference in speed during the
brake test.
This prevents brake forces being transferred to the drive train.
The forward rotating wheel is measured during the test, which
means two brake tests per axle must be performed. gen AG
. Volkswagen AG
d a oes
lksw not
The maximum test speed must not exceed 6 km/h.
db
yV
o gu
ara
e nte
ris
The test rigs authorised by Volkswagen fulfil
ut these requirements.
ho eo
ra
a c
ss
ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

8 Rep. Gr.00 - Technical data

 Touareg 2003 ➤
Brake systems - Edition 07.2009

45 – Anti-lock brake system

1 General notes for anti-lock brake sys‐
tem (ABS)
On vehicles with ABS Mark 25, only the following version is in‐
stalled:
♦ ABS/EDL/TCS with electronic stabilisation program (ABS/
EDL/TCS/ESP)
The ABS brake system is divided diagonally. The servo-assis‐
tance is effected pneumatically by the vacuum brake servo unit.
Faults in the ABS influence the brake system and servo assis‐
tance. A change in braking behaviour is to be reckoned with. After
the ABS warning lamp comes on, the rear wheels may lock pre‐
maturely during braking!
Models with ABS Mark 25 do not have a mechanical brake pres‐
sure regulator. Specially matched software in the control unit
regulates the brake force distribution on the rear axle.
The hydraulic unit -2- and control unit -1- form one component.
They can be separated only when removed. Hydraulic pump -3-
must not be separated from hydraulic unit.
New control units from the replacement parts service are not co‐
ded. They must be coded once installed. ⇒ Coding control unit
using VAS 5051 via function "Guided fault finding".
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
ABS layout in left-hand drive vehicle.
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

1. General notes for anti-lock brake system (ABS) 9

 Touareg 2003 ➤
Brake systems - Edition 07.2009 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
d
2 Notes for repair work on the ABS ise nte
or eo
h
aut ra
s c
♦ Before carrying out repair work on the anti-lock brake system, s

ce
le
determine the cause of the fault using “Guided Fault Finding”.

un

pt
an
d
itte

y li
“Guided fault finding” is carried out on the vehicle diagnosis, test‐

rm

ab
ing and information system -VAS 5051- .

pe

ility
ot

wit
, is n
♦ Before working on the anti-lock brake system, disconnect the

h re
battery earth strap. Note or request radio code on vehicles with

hole

spec
coded radio if necessary.

es, in part or in w

t to the co
♦ Before carrying out welding work with an electric welding unit,
note ⇒ General Information; Body Repairs, General Body Re‐
pairs .

rrectness of i
♦ When working with brake fluid, observe the relevant safety
l purpos

precautions and notes ⇒ page 133 .

♦ After work for which the brake system had to be opened, bleed

nform
ercia

the brake system with brake filling and bleeding equipment -

VAS 5234- or -V.A.G 1869- ⇒ page 133 .
m

a
com

tio
♦ During the final road test, ensure that a controlled brake test

n in
r
te o

is performed at least once (pulsations must be felt at the brake

thi
s
pedal).
iva

do
r
rp

cum
♦ Absolute cleanliness is required when working on the anti-lock
fo

en
ng

brake system. It is not permitted to use any products which

t.
yi Co
op
contain mineral oil, such as oils, greases etc.
C py
ht. rig
rig ht
py by
♦ Thoroughly clean all unions and the adjacent areas before co Vo
by lksw
loosening. Do not use aggressive cleaning agents such as
cted agen
Prote AG.
brake cleanser, petrol, thinners or similar.
♦ Place removed parts on a clean surface and cover.
♦ If repairs cannot be carried out immediately, carefully cover or
seal open components. ( Sealing plugs -1 H0 698 311 A-
should be used).
♦ Only use lint-free cloths.
♦ Only unpack replacement parts immediately prior to fitting.
♦ Only use genuine packed parts.
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ Ensure that no brake fluid enters connectors.
♦ 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).

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

 Touareg 2003 ➤
Brake systems - Edition 07.2009

3 Connecting -VAS 5051- and select‐

ing functions
Special tools and workshop equipment required
♦ -VAS 5051- Vehicle Diagnosis, Testing and Information Sys‐
tem n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
ss

ce
le
un

pt
an
d
itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
♦ Diagnosis lead -VAS 5051/1- or -VAS 5051/3-

rrectne
WARNING

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

ss o
measuring equipment on the back seat.
cial p

f inform
♦ These devices may be operated only by a passenger while
mer

the vehicle is in motion.

atio
om

n
c

i
or

n thi
te

sd
– Connect connector of diagnostic cable -VAS 5051/1- or -
iva

o
r

VAS 5051/3- to diagnostic cable -arrow-.

p

cum
r
fo

en
ng

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

3. Connecting VAS 5051 and selecting functions 11

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Switch on tester -arrow-.

The tester is ready for operation when the selector buttons for the
operating modes appear on the screen.
– Switch on ignition.
– Touch Guided Fault Finding on screen.
– Select one after another:
♦ Brand
♦ Type
♦ Model year
♦ Body version
♦ Engine code
– Confirm data entered.
Wait until tester has interrogated all control units in vehicle.
Volkswa
– Press Go to and select function “Function/component
agen
AG. selec‐gen AG d
oes
lksw not
tion”. by Vo gu
a d ran
ise
– Select “Running gear” on display.uthor tee
or
sa ac
– Select “Brake systems” on display.
s

ce
e
nl

pt
du

– Select “01 Self-diagnosis capable system …” shown on dis‐

an
itte

y li
play.
erm

ab
ility
ot p

– Select “Anti-lock brake system …” shown on display.

wit
, is n

h re
– Select “Function” shown on display.
hole

spec
Now all possible functions from the anti-lock brake system instal‐
es, in part or in w

t to the co
led in the vehicle will be displayed.
– Select desired function on display.
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

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

 Touareg 2003 ➤
Brake systems - Edition 07.2009

4 Electrical/electronic components and fitting locations

1 - ABS hydraulic unit -N55-

❑ Location: on right in ple‐
num chamber.
The hydraulic unit consists of
the components:
❑ ABS hydraulic pump -
V64-
❑ Valve block (contains in‐
let and outlet valves).
❑ ABS hydraulic pump -
V64- and valve block AG. Volkswagen AG d
must not be separated agen oes
olksw not
from one another. d by V gu
ara
ise nte
❑ From week 48/06 with thor eo
brake pressure sender - ss au ra
c
G201-

ce
e
nl

pt
du

an
2 - ABS control unit -J104-
itte

y li
erm

ab
❑ Fitting location: on the

ility
ot p

hydraulic unit on right in

wit
plenum chamber.
, is n

h re
hole

❑ Do not separate con‐

spec
nector before success‐
es, in part or in w

fully completing self-di‐

t to the co
agnosis. Switch ignition
off before disconnecting
connector.

rrectness of i
3 - Brake pressure sender -
l purpos

G201-
❑ Location: to week 48/06

nform
ercia

on brake master cylin‐

der
m

at
om

io
❑ Removing and installing

n
c

in t
or

⇒ page 138 his

ate

do
riv

❑ From week 48/06 in

p

ABS hydraulic unit -

um
for

en
g

N55-
n

t.
yi Co
Cop py
4 - Brake servo pressure sensor -G294-
t. rig
gh ht
yri by
❑ Installed only in vehicles with a petrol engine and an automatic gearbox. cop Vo
by lksw
cted agen
❑ Fitting location: in vacuum hose to brake servo.
Prote AG.

5 - Vacuum pump for brakes -V192-

❑ Installed only in vehicles with a petrol engine and an automatic gearbox.
❑ Fitting location: front right in engine compartment.
❑ Removing and installing ⇒ page 140
6 - ESP and TCS warning lamp -K155-
❑ Fitting location: in dash panel insert.
Function: ⇒ page 15 .

7 - ABS warning lamp -K47-

❑ Fitting location: in dash panel insert.
Function: ⇒ page 15 .

4. Electrical/electronic components and fitting locations 13

 Touareg 2003 ➤
Brake systems - Edition 07.2009

8 - Brake system warning lamp -K118-

❑ Fitting location: in dash panel insert.
Function: ⇒ page 15 .

9 - TCS and ESP button -E256-

❑ Fitting location: in centre console.
10 - ESP sensor unit -G419-
❑ Fitting location: under centre console.
❑ Combined lateral acceleration sender -G200- , yaw rate sender -G202- and longitudinal acceleration
sender -G251-
❑ Combined in one housing.
❑ Observe installation instructions ⇒ page 34 .
11 - Steering angle sender -G85-
❑ Fitting location: on steering column between steering wheel and steering column switch.
❑ Observe installation instructions ⇒ page 35 .
12 - Diagnostic connection
❑ Fitting location: driver side footwell cover.
❑ ⇒ page 14
13 - Brake light switch -F- and brake pedal switch -F47-
❑ Removing and installing ⇒ page 112 agen
AG. Volkswagen AG d
oes
lksw not
❑ Vehicles from week 48 of 2006 do not have db
y V a brake light switch.
o gu
a
e ran
ris tee
14 - Front right speed sensor -G45- / front tholeft speed sensor -G47- or
au ac
❑ Renewing ⇒ page 31 ss

ce
e
nl

pt
15 - Wheel hub with wheel bearing
du

an
itte

y li
❑ ABS sensor ring is installed in the wheel bearing.
erm

ab
ility
ot p

16 - Rear right speed sensor -G44- / rear left speed sensor -G46-
wit
, is n

h re
❑ Renewing ⇒ page 33
hole

17 - Wheel hub with wheel bearing spec

es, in part or in w

t to the co
❑ ABS sensor ring is installed in the wheel bearing.
rrectness of i

Diagnostic connection
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

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

 Touareg 2003 ➤
Brake systems - Edition 07.2009

5 Fault display via warning lamps

Warning lamps
Item Description
1 ESP and TCS warning lamp -K155-
2 Brake pad warning lamp -K32-
3 ABS warning lamp -K47-
4 Brake system warning lamp -K118-
ABS warning lamp -K47-

♦ If the ABS warning lamp -K47- -3- does not go out after the
ignition has been switched on and test sequence has been
completed, then the fault may be:
a - Voltage supply is below 10 Volt.
b - There is a fault in the ABS
AG. Volkswagen n AG do
wage e
In the event of an y V ABS fault -b-, the anti-lock brake
olks s no
t gu system re‐
mains switched
rised b off, but the brake system remains fully ara operation‐
nte
al. ut
ho eo
r
sa ac
c - Since
s
the last time the vehicle was started there was a tem‐
ce
e
nl

porary speed sensor fault.

pt
du

an
itte

y li

In this case, ABS warning lamp -K47- will go out automatically

erm

ab

after the engine is restarted and the vehicle exceeds a speed of

ility
ot p

2.75 km/h (approx. 13 mph).

wit
, is n

h re

d - The connection from dash panel insert to control unit for ABS
hole

spec

with EDL -J104- is interrupted. ⇒ Current flow diagrams, Electrical

es, in part or in w

fault finding and Fitting locations

t to the co

e - The ABS warning lamp -K47- is defective.

rrectness of i

ABS warning lamp -K47- and brake system warning lamp -K118-
l purpos

♦ If the ABS warning lamp -K47- -3- goes out but the brake sys‐
tem warning lamp -K118- -4- remains on, then the fault may
nf
ercia

be:
orm
m

a - The brake fluid level is too low.

atio
om

n in
c

Three warning tones are audible after ignition is switched on.

or

thi
te

sd
a

b - There is a fault in the wiring to the brake system warning lamp

iv

o
r
rp

cu

-K118- ⇒ Current flow diagrams, Electrical fault finding and Fitting

o

m
f

locations.
en
ng

t.
yi Co
op py
♦ If the ABS warning lamp -K47- -3- and the brake system warn‐
. C rig
ht ht
ing lamp -K118- -4- light up, then the anti-lock brake system
rig by
opy Vo
is defective. A change in braking behaviour is to be reckoned
by c lksw
cted agen
with.
Prote AG.

WARNING

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

5. Fault display via warning lamps 15

 Touareg 2003 ➤
Brake systems - Edition 07.2009

ESP and TCS warning lamp -K155-

♦ If the ESP and TCS warning lamp -K155- -1- does not go out
after the ignition has been switched on and the test sequence
has been completed, then the fault may be:
A fault in the system affecting only the TCS/ESP. The ABS/EDL
and EBD safety systems on the vehicle remain fully functional ⇒
Interrogate fault memory.
a - Short circuit to positive in TCS and ESP button -E256- .
b - Short circuit to earth in wire controlling ESP and TCS warning
lamp -K155- .
c - Open circuit in connection from dash panel insert to contact
31 of ABS control unit -J104- .
d - The TCS/ESP system has been switched off by the TCS and
ESP button -E256- .
If the ESP and TCS warning lamp -K155- flashes during travel,
the TCS or ESP system is regulating the system.

♦ If the ESP and TCS warning lamp -K155- -1- does not light up
during the self-test, the fault may be:
a - The ESP and TCS warning lamp -K155- is defective ⇒ perform
electrical check.
ABS warning lamp -K47- and ESP and TCS warning lamp -K155-
. Volkswagen AG
♦ If the ABS warning lamp -K47- -3- and the ESPkand gen AG
swa TCS does
not
Vol ignition has
warning lamp -K155- -1- do not go out afterbythe gu
ara
been switched on and after the test sequence
ris
ed has been com‐ nte
pleted, then the fault may be: au
tho eo
ra
ss c
a - Voltage supply for anti-lock brake system (ABS) is below
ce
e
nl

10 volts and vehicle speed is less than 12 km/h ⇒ Performing pt

du

an
itte

electrical test. y li
erm

ab
b - Short circuit to earth in wire controlling ESP and TCS warning ility
ot p

lamp -K155- .
wit
, is n

h re
hole

- Short circuit to positive in TCS and ESP button -E256- .

spec
es, in part or in w

t to the co

ABS warning lamp -K47- , brake system warning lamp -K118- and
ESP and TCS warning lamp -K155-
♦ If the ABS warning lamp -K47- -3-, the ESP and TCS warning
rrectness of i

lamp -K155- -1- and the brake system warning lamp -K118-
l purpos

-4- do not go out, then the fault may be:

a - Voltage supply for anti-lock brake system (ABS) is below
nform
ercia

10 volts and vehicle speed is less than 12 km/h ⇒ Performing

electrical test.
m

at
om

io

b - There is a fault in the hydraulic control unit; the anti-lock brake

n
c

in t
or

system (ABS) is not operational.

his
ate

do
riv

A change in braking behaviour is to be reckoned with. The rear

p

cum
or

wheels can lock early when braking!

f

en
ng

t.
yi Co
c - A dynamic speed sensor fault was present during the last driv‐ Cop py
. rig
en period.
ht ht
rig by
copy Vo
lksw
In this case, the warning lamps go out automatically after the ve‐
by
cted agen
Prote
hicle is restarted and a speed of 2.75 km/h is exceeded. The
AG.

prerequisite is that the fault on the speed sensor no longer occurs

after fault rectification and repeating check.

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

 Touareg 2003 ➤
Brake systems - Edition 07.2009

Brake system warning lamp -K118-

♦ If the brake system warning lamp -K118- -4- does not go out
after the ignition has been switched on, the fault may be:
a - The foot-operated parking brake is applied.
AG. Volkswagen
- The switch for the brake systemlksw warning lamp -K118- is
agen AG do
es ndefec‐
tive or incorrectly adjusted.
db
yV
o ot g
ua
e ran
ris tee
- There is a wiring fault
ut ⇒ Performing electrical test.
ho or
sa ac
The parking brakes contact switch also informs the ABS control

ce
e
nl

unit -J104- as to whether the foot-operated parking brake is ap‐

pt
du

an
plied or released. When the foot-operated parking brake is ap‐
itte

y li
plied, ESP control is negatively influenced.
erm

ab
ility
ot p

wit
, is n

Brake pad warning lamp -K32-

h re
hole

spec
♦ If the brake pad warning lamp -K32- -2- does not go out 3 sec‐
es, in part or in w

onds after the ignition is switched on, or it if comes on during

t to the co
vehicle operation, the fault may be:
a - The brake pads/linings are worn.

rrectness of i
Check brake pads/linings on front and rear axles. Renew worn
l purpos

brake pads/linings.
b - There is a wiring fault. ⇒ Current flow diagrams, Electrical fault

nf
ercia

finding and Fitting locations

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

5. Fault display via warning lamps 17

 Touareg 2003 ➤
Brake systems - Edition 07.2009
AG. Volkswagen AG d
agen oes
ksw
6 Assembly overview - hydraulic unit, ol not
byV gu
ara
ed
is nte
brake servo/brake master cylinder or eo
h
aut ra
ss c

ce
e
nl

pt
du

an
6.1 ABS MK 25 to week 48/06

itte

y li
erm

ab
ility
ot p

wit
, is n
1 - ABS control unit -J104-

h re
hole
❑ Removing and installing

spec
⇒ page 21
es, in part or in w

t to the co
2 - ABS hydraulic unit -N55-
❑ Removing and installing

rrectness of i
⇒ page 21
l purpos

3 - Brake line
❑ From primary piston cir‐
cuit of brake master cyl‐

nform
ercia

inder to hydraulic unit

m

at
❑ Marked on hydraulic
om

ion
unit with -DK-.
c

in t
or

his
te

4 - Brake line
a

do
priv

c
❑ From secondary piston

um
for

en
g

circuit of brake master

n

t.
yi Co
cylinder to hydraulic unit ht. Cop py
rig
❑ Marked on hydraulic rig ht
py by
Vo
unit with -SK-.
co lksw
by
cted agen
Prote AG.
5 - Brake line
❑ To rear left caliper via in‐
termediate piece.
❑ Marked on hydraulic
unit with -HL-
6 - Brake line
❑ To front right brake cali‐
per via intermediate
piece.
❑ Marked on hydraulic
unit with -VR-
7 - Brake line
❑ To front left brake cali‐
per
❑ Marked on hydraulic unit with -VL-
8 - Brake line
❑ To rear right caliper via intermediate piece.
❑ Marked on hydraulic unit with -HR-
9 - Intermediate piece
10 - Bracket
❑ Allocation ⇒ Electronic Parts Catalogue (ETKA) .
11 - Hexagon flange bolt, 5 Nm
12 - Hexagon bolt, 8 Nm
13 - Buffer
14 - Seal
❑ For brake servo.

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

 Touareg 2003 ➤
Brake systems - Edition 07.2009

15 - Tandem brake servo

❑ Including brake pressure solenoid trip switch -F84- and brake pressure solenoid valve -N247- (cannot
be renewed)
❑ On petrol engines, the required vacuum is taken from the intake manifold.
❑ Vehicles with a petrol engine and an automatic gearbox are equipped with a brake vacuum pump.
❑ Diesel engines are fitted with a vacuum pump to create the required vacuum.
❑ Functional check:
– With engine switched off, depress brake pedal firmly several times (to exhaust vacuum in unit).

– Now step on and hold brake pedal with medium pressure and start engine. If the brake servo is functioning
properly, the brake pedal will be felt to go down as the servo takes effect.
❑ If faulty renew complete (check all vacuum lines first).
❑ Removing and installing ⇒ page 144
16 - Sealing ring
17 - Potentiometer for brake servo diaphragm travel
wage
n-G420-
AG. Volkswagen AG d
oes
lks not
❑ Removing and installing ⇒ page 137 d byV
o gu
ara
e nte
❑ Discontinued from week 48/06thoris eo
au ra
18 - Snap ring ss c

ce
e
nl

pt
19 - Sealing plug
du

an
itte

y li
❑ Connection for vacuum hose
erm

ab
ility
ot p

20 - Vacuum hose

wit
, is n

h re
❑ Fit in brake servo
hole

spec
21 - Sealing ring
es, in part or in w

t to the co
22 - Hexagon nut, self locking, 25 Nm
❑ Always renew after removing

rrectness of i
23 - Brake pressure sender -G201-
l purpos

❑ Removing and installing ⇒ page 138

❑ From week 48/06 in ESP unit
nform
ercia

24 - Bracket
m

at
om

25 - Brake master cylinder

ion
c

in t
r

❑ Cannot be repaired. If faulty, renew complete.

o

his
ate

❑ Removing and installing ⇒ page 142 .

do
priv

cum
or

26 - Sealing plug
f

en
ng

t.
yi Co
❑ Moisten with brake fluid and press into brake fluid reservoir. Cop py
t. rig
gh ht
yri
27 - Brake fluid reservoir p by
co Vo
by lksw
cted agen
28 - Cap Prote AG.

29 - Torx bolt, 4 Nm

6. Assembly overview - hydraulic unit, brake servo/brake master cylinder 19

 Touareg 2003 ➤
Brake systems - Edition 07.2009

Connecting brake lines from brake master cylinder to hydraulic

unit
On brake master cylinder:

On hydraulic unit:
A - From hydraulic unit to primary piston circuit of brake master
cylinder.
- Marked on hydraulic unit with -DK-.
B - From hydraulic unit to secondary piston circuit of brake master
cylinder.
- Marked on hydraulic unit with -SK-.
1 - From hydraulic unit to front left brake caliper.
- Marked on hydraulic unit with -VL-
gen AG
. Volkswagen AG
d wa oes
olks no
2 - Hydraulic unit todfront
by
V right brake caliper via intermediate
t gu
ar piece.
e an
ris tee
- Marked on hydraulic
ut
ho unit with -VR- or
a ac
ss
3 - Hydraulic unit to rear right brake caliper via intermediate piece.
ce
e
nl

pt
du

an

- Marked on hydraulic unit with -HR-

itte

y li
erm

ab

4 - Hydraulic unit to rear left brake caliper via intermediate piece.

ility
ot p

wit

- Marked on hydraulic unit with -HL-

, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

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

 Touareg 2003 ➤
Brake systems - Edition 07.2009

6.1.1 Removing and installing control unit and

hydraulic unit
Special tools and work‐
shop equipment re‐
quired
♦ Torque wrench -
V.A.G 1410-

♦ Brake pedal depres‐

sor -V.A.G 1869/2-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut
Sealings aplugs repair kit, ra
c
Part No. 1H0 698 311 A
s
ce
le
un

pt

The transport protection

an
d
itte

y li

for the contact pins must

rm

ab

always be placed on the

pe

ility
ot

hydraulic unit after the

wit
, is n

control unit has been dis‐

h re
hole

connected from the hy‐

spec

draulic unit.
es, in part or in w

t to the co

No warranty can be as‐

sumed for hydraulic units
without transport protec‐
rrectness of i

tion.
l purpos

1 - Transport protection
for contact pins (foam)
nform
ercia

2 - Sealing plug M 10
m

a
com

3 - Sealing plug M 12
ion in
r
te o

Fitting location:
thi
s
iva

do
r

The control unit is bolted

rp

cum
fo

to the hydraulic unit and

en
ng

t.
yi
is located on right in ple‐
Co
op py
num chamber. t. C rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

6. Assembly overview - hydraulic unit, brake servo/brake master cylinder 21

 AG. Volkswagen AG d
agen oes
ksw
Touareg 2003 ➤ by
Vol not
gu
d ara
Brake systems - Edition o07.2009
ris
e nte
h eo
aut ra
ss c

ce
le
WARNING

un

pt
an
d
itte

y li
Do not bend the brake
erm

ab
ility
lines in the area of the ot p

wit
hydraulic unit!
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
6.1.2 Removing control unit and hydraulic unit
– Note or request radio code on vehicles with coded radio if

rrectne
necessary.
– Disconnect battery ⇒ Electrical system; Rep. Gr. 27 ; Dis‐

ss
connecting and reconnecting battery .

o
cial p

f inform
– Remove plenum chamber cover ⇒ General body repairs, ex‐
mer

terior; Rep. Gr. 64 ; Flush bonded windows; Removing and

atio
m

installing plenum chamber cover .

o

n
c

i
or

n
– Remove engine control unit.

thi
te

sd
iva

o
r

– Unbolt earth wire from body behind bracket for engine control
p

cum
r
fo

unit.

en
ng

t.
yi Co
op
– Unclip wiring harness and lay it to side. C py
t. rig
gh ht
yri by
– Remove bracket for engine control unit. op Vo
by c lksw
cted agen
Prote
– Remove intake duct ⇒ Heating, air conditioning system; Rep.
AG.

Gr. 87 ; Dismantling and assembling air conditioner unit .

– Release control unit connector in direction of arrow -1- and pull
off (arrow -2-).
– Connect bleeder bottle hose to front left brake caliper bleeder
valve and open bleeder valve.
– Apply brake pedal depressor -V.A.G 1869/2- .
– Close front left bleeder valve.
– Place sufficient lint-free cloths under the control unit and hy‐
draulic unit.
Ensure no brake fluid gets onto contacts.
– Mark brake lines and unscrew from hydraulic unit and inter‐
mediate piece.
– Seal brake lines and threaded holes using sealing plugs
-1H0 698 311 A- .

– Unbolt hydraulic unit from bracket -arrows-.

– Take hydraulic unit along with control unit out upwards.

6.1.3 Unbolting control unit from hydraulic unit

– Place hydraulic unit with control unit on a clean flat level sur‐
face.

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

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Remove external Torx screws -arrows-.

– Without canting it, pull control unit off from hydraulic unit
-arrow-.

WARNING

♦ No moisture or particles of dirt may enter control unit.

n AG. Volkswagen AG do
wage es n
♦ Hydraulic pump must not be separated from hydraulic y V unit.
olks ot g
ua
d b ran
ir se tee
tho
u or
– Cover control unit solenoids with a lint-free
ss cloth.
a ac

ce
le
un

After separating control unit and hydraulic unit, use transport pro‐

pt
an
d

tection for contact pins.

itte

y li
erm

ab
ility
ot p

6.1.4 Installing new control unit

wit
is n

h re
ole,

spec
urposes, in part or in wh

WARNING

t to the co
Severe shocks (e.g. dropping, impact) may destroy control
unit. The control unit must not then be used.

rrectnes
• Clean surfaces before assembling.

s o
cial p

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

inform
mer

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

socket head bolts.

o

n
c

i
or

n thi
te

sd
va

Note
i

o
pr

cum
r
fo

en
ng

t.
♦ It is not possible to fit a new control unit more than twice to an
yi Co
op py
installed hydraulic unit to ensure that the flexible seal is free t. C rig
gh ht
of leaks. yri
p by
co Vo
by lksw
cted
♦ A control unit which has already been operated in a vehicle
agen
Prote AG.
must not be installed a second time.

6.1.5 Installing control unit and hydraulic unit

Note

♦ Remove sealing plugs from new hydraulic unit only when the
corresponding brake line is going to be fitted.
♦ If sealing plugs are removed too early from the hydraulic unit,
brake fluid can escape, and it can then no longer be guaran‐
teed that the unit can be sufficiently filled and bled.

6. Assembly overview - hydraulic unit, brake servo/brake master cylinder 23

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Install in reverse order.

– Remove brake pedal depressor -V.A.G 1869/2- .
– Bleed brake system ⇒ page 133 .
– Code radio.
– Code ABS control unit -J104- with ⇒ Vehicle diagnosis, testing
and information system VAS 5051 in “Guided fault finding”.
– Basic setting must additionally be performed when ABS con‐
trol unit -J104- is replaced.
Torque settings
Control unit to hydraulic unit max. 4 Nm
Hexagon bolt of hydraulic unit to bracket 8 Nm
Brake lines to ABS unit:
Thread M 10 x 1 14 Nm
Thread M 12 x 1 14 Nm

6.2 ABS MK 25 E1 from week 48/06

1 - ABS control unit -J104-

❑ Removing and installing
⇒ page 27
2 - ABS hydraulic unit -N55-
❑ Removing and installing
⇒ page 27
3 - Brake line
❑ From primary piston cir‐
cuit of brake master cyl‐
inder to hydraulic unit
❑ Marked on hydraulic
unit with -DK-. . Volkswagen AG
gen AG does
swa
4 - Brake line by
Vol
k not
gu
d ara
❑ To front right brake cali‐horise nte
eo
per via intermediate aut ra
c
piece. ss
ce
e
nl

❑ Marked on hydraulic
pt
du

an
itte

unit with -VR-

y li
erm

ab

5 - Brake line
ility
ot p

wit
, is n

❑ To front left brake cali‐

h re

per
hole

spec

❑ Marked on hydraulic
es, in part or in w

t to the co

unit with -VL-

6 - Brake line
rrectness of i

❑ From secondary piston

circuit of brake master
l purpos

cylinder to hydraulic unit

❑ Marked on hydraulic
nform
ercia

unit with -SK-.

m

7 - Brake line
at
om

ion

❑ To rear left caliper via in‐

c

in t
or

termediate piece.
his
ate

do
riv

❑ Marked on hydraulic unit with -HL-

p

cum
for

en

8 - Brake line
ng

t.
yi Co
op
❑ To rear right caliper via intermediate piece.
C py
t. rig
gh ht
pyri by
Vo
o

24
c by lksw
cted agen
Rep. Gr.45 - Anti-lock brake system Prote AG.
 Touareg 2003 ➤
Brake systems - Edition 07.2009
❑ Marked on hydraulic unit with -HR-
9 - Intermediate piece
10 - Bracket
❑ Allocation ⇒ Electronic Parts Catalogue (ETKA) .
11 - Bolt, 8 Nm
12 - Hexagon flange bolt, 9 Nm
13 - Rubber damper
14 - Bracket
❑ Allocation ⇒ Electronic Parts Catalogue (ETKA) .
15 - Seal
❑ For brake servo.
16 - Tandem brake servo
❑ Including brake pressure solenoid trip switch -F84- and brake pressure solenoid valve -N247- (cannot
be renewed)
❑ On petrol engines, the required vacuum is taken from the intake manifold.
❑ Vehicles with a petrol engine and an automatic gearbox are equipped with a brake vacuum pump.
❑ Diesel engines are fitted with a vacuum pump to create the required vacuum.
❑ Functional check:
– With engine switched off, depress brake pedal firmly several times (to exhaust vacuum in unit).

– Now step on and hold brake pedal with medium pressure and start engine. If the brake servo is functioning
properly, the brake pedal will be felt to go down as the servo takes effect.
❑ If faulty renew complete (check all vacuum lines first).
❑ Removing and installing ⇒ page 144
17 - Sealing plug
❑ Connection for vacuum hose
n AG. Volkswagen AG do
18 - Vacuum hose
olks
wage es n
ot g
yV
❑ Fitsin
ed brake servo
b ua
ran
ri tee
ho
19 - Sealing
au
t ring or
ac
ss
20 - Self-locking hexagon nut, 25 Nm
ce
e
nl

pt
du

an

❑ Always renew after removing

itte

y li
erm

ab

21 - Bracket
ility
ot p

wit
, is n

22 - Brake master cylinder

h re
hole

❑ Cannot be repaired. If faulty, renew as a complete unit.

spec
es, in part or in w

❑ Removing and installing ⇒ page 142

t to the co

23 - Self-locking hexagon nut, 25 Nm

❑ Always renew after removing
rrectness of i

24 - Sealing plug
l purpos

❑ Moisten with brake fluid and press into brake fluid reservoir.
25 - Brake fluid reservoir
nform
ercia

26 - Cap
m

at
om

ion

27 - Torx bolt, 2+0.8 Nm

c

in t
or

his
e

❑ Without canting, tighten in stages using diagonal sequence.

at

do
priv

cum
for

en
ng

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

6. Assembly overview - hydraulic unit, brake servo/brake master cylinder 25

 Touareg 2003 ➤
Brake systems - Edition 07.2009

Connecting brake lines from brake master cylinder to hydraulic

unit
On brake master cylinder:

On hydraulic unit:
A - From hydraulic unit to primary piston circuit of brake master
cylinder.
- Marked on hydraulic unit with -DK-.
B - From hydraulic unit to secondary piston circuit of brake master
cylinder.
- Marked on hydraulic unit with -SK-.
1 - From hydraulic unit to front left brake caliper.
- Marked on hydraulic unit with -VL-
2 - Hydraulic unit to front right brake caliper via intermediate piece.
- Marked on hydraulic unit with -VR-
3 - Hydraulic unit to rear right brake caliper via intermediate piece.
- Marked on hydraulic unit with -HR-
4 - Hydraulic unit to rear left brake caliper via intermediate piece.
- Marked on hydraulic unit with -HL-
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

26
c by lksw
cted agen
Rep. Gr.45 - Anti-lock brake system Prote AG.
 Touareg 2003 ➤
Brake systems - Edition 07.2009
AG. Volkswagen AG d
agen oes
olksw not
6.2.1 Removing and installing control unit and
y V gu
d b ara
ise nte
hydraulic unit or eo
th
au ra
ss c
Special tools and work‐

ce
le
un

pt
shop equipment re‐

an
d
itte

quired

y li
erm

ab
ility
♦ Torque wrench -
ot p

wit
V.A.G 1410-
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

♦ Brake pedal depres‐

i
or

n thi
sor -V.A.G 1869/2-
te

sd
iva

o
pr

cum
r
fo

en
ng

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

Sealing plugs repair kit,

Part No. 1H0 698 311 A
The transport protection
for the contact pins must
always be placed on the
hydraulic unit after the
control unit has been dis‐
connected from the hy‐
draulic unit.
No warranty can be as‐
sumed for hydraulic units
without transport protec‐
tion.
1 - Transport protection
for contact pins (foam)
2 - Sealing plug M10
3 - Sealing plug M12
Location:
The control unit is bolted
to the hydraulic unit and
is located on right in ple‐
num chamber.

6. Assembly overview - hydraulic unit, brake servo/brake master cylinder 27

 Touareg 2003 ➤
Brake systems - Edition 07.2009

WARNING

Do not bend the brake

lines in the area of the
hydraulic unit!

6.2.2 Removing control unit and hydraulic unit lksw

agen
AG. Volkswagen AG d
oes
not
Vo gu
y
– Note or request radio code on vehicles with coded radio if rised b ara
nte
necessary. utho eo
ra
s a c
– Disconnect battery ⇒ Electrical system; Rep. Gr. 27 ; Dis‐ s

ce
e
nl
connecting and reconnecting battery .

pt
du

an
itte

y li
– Remove plenum chamber cover ⇒ General body repairs, ex‐
erm

ab
terior; Rep. Gr. 64 ; Flush bonded windows; Removing and

ility
ot p

installing plenum chamber cover .

wit
, is n

h re
– Remove engine control unit.
hole

spec
es, in part or in w

– Unbolt earth wire from body behind bracket for engine control

t to the co
unit.
– Unclip wiring harness and lay it to side.

rrectness of i
– Remove bracket for engine control unit.
l purpos

– Remove intake duct ⇒ Heating, air conditioning system; Rep.

Gr. 87 ; Dismantling and assembling air conditioner unit .

nform
ercia

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

m

off (arrow -2-).

at
om

ion
c

– Connect bleeder bottle hose to front left brake caliper bleeder

in t
or

his
e

valve and open bleeder valve.

at

do
priv

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

um
for

en
ng

t.
– Close front left bleeder valve.
yi Co
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t. rig
– Place sufficient lint-free cloths under the control unit and hy‐
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pyri by
draulic unit.
co Vo
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Ensure no brake fluid gets onto contacts.
– Mark brake lines and unscrew from hydraulic unit and inter‐
mediate piece.
– Seal brake lines and threaded holes using sealing plugs
-1H0 698 311 A- .

– Take hydraulic unit along with control unit out upwards out of
the shock absorbers.
– Unbolt hydraulic unit from bracket.

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

 Touareg 2003 ➤
Brake systems - Edition 07.2009

6.2.3 Unboltingagcontrol
en AG. V unit
olkswagenfrom
AG do hydraulic unit
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– Place hydraulic unit with control unit upwards on a clean flat

itte

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level surface.
rm

ab
pe

ility
– Unscrew Torx bolts out of control unit.
ot

wit
, is n

h re
– Without canting it, pull control unit off from hydraulic unit
hole

spec
-arrow-.
es, in part or in w

t to the co
– Carefully pull all seals from hydraulic unit contact pins.

WARNING

rrectness of i
l purpos

♦ Printed circuit board becomes visible when control unit is

removed.

nform
ercia

♦ No moisture or particles of dirt may enter control unit.

m

a
♦ Avoid electrostatic charge!
com

tion in
r
te o

thi
s
iva

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

r
rp

cum
fo

After separating control unit and hydraulic unit, use transport pro‐
en
ng

t.
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tection for contact pins. t. Cop py
rig
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pyri by
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Prote AG.

6.2.4 Installing new control unit

WARNING

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

unit. Control unit must not then be used.

• Clean surfaces before assembling.

– Push all seals -A- over contact pins slightly.
– Without canting it, place control unit onto hydraulic unit.
The seals are thus moved to end position.
– Tighten hydraulic unit and control unit diagonally in stages to
specified torque with enclosed new Torx bolts.

Note

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

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

6. Assembly overview - hydraulic unit, brake servo/brake master cylinder 29

 Touareg 2003 ➤
Brake systems - Edition 07.2009

6.2.5 Installing control unit and hydraulic unit

Note

♦ Remove sealing plugs from new hydraulic unit only when the
corresponding brake line is going to be fitted.
♦ If sealing plugs are removed too early from the hydraulic unit,
brake fluid can escape, and it can then no longer be guaran‐
teed that the unit can be sufficiently filled and bled.

– Install in reverse order.

– Before installing bracket for ABS hydraulic unit -N55- in ple‐
num chamber, spray rubber dampers with silicone lubricant
D 007 000 A2 to make installation easier.
gen AG
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d a oes
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th eo
s au ra
c
Ensure that rubber dampers are
not pressed out of bracket
s

ce
le

when installing. After installing, check hydraulic unit with con‐

un

pt
an
trol unit for proper seating, otherwise malfunctions can occur.
d
itte

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erm

ab
ility
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wit
– Remove brake pedal depressor -V.A.G 1869/2- .
is n

h re
ole,

– Bleed brake system ⇒ page 133 .

spec
urposes, in part or in wh

– Code radio. t to the co

– Code ABS control unit -J104- with ⇒ Vehicle diagnosis, testing
and information system VAS 5051 in “Guided fault finding”.
rrectne

– Basic setting must additionally be performed when ABS con‐

trol unit -J104- is replaced.
ss o
cial p

Specified torques:
inform
mer

Control unit to hydraulic unit 2 Nm + 0.8

atio

♦ Use new bolts! Nm

om

n
c

i
or

n thi

Bolt for bracket on hydraulic unit 8 Nm

te

sd
va

Brake lines to ABS unit:

i

o
pr

cum
r
fo

Thread M10 x 1 14 Nm
en
ng

t.
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op
Thread M12 x 1 14 Nm
C py
t. rig
gh ht
pyri by
Vo
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by c lksw
cted agen
Prote AG.

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

 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
horis nte
eo Touareg 2003 ➤
aut ra Brake systems - Edition 07.2009
ss c

ce
le
un

pt
an
d
7 itte
Removing and installing parts of ABS system on front and rear axle

y li
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ab
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1 - ABS speed sensor

h re
hole

❑ Before inserting sensor,

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

t to the co
surface and coat with
polycarbamide grease -
G 052 142 A2- .

rrectness of i
❑ Removing and installing
⇒ page 31
l purpos

2 - Hexagon socket head bolt,

8 Nm

nform
ercia

3 - Wheel hub with wheel bear‐

m

a
com

ti
ing

on in
r
te o

❑ ABS sensor ring is in‐

thi
s
stalled in the wheel
iva

do
r

bearing.
rp

cum
fo

en
ng

4 - Drive shaft
t.
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Prote AG.

7.1 Removing and installing speed sensor

on front axle

7.1.1 Removing
– Raise vehicle.

7. Removing and installing parts of ABS system on front and rear axle 31
 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Separate connector -1- from speed sensor wire and from

speed sensor.
– Remove bolt -2- from wheel bearing housing.
– Pull ABS speed sensor out of wheel bearing housing.

7.1.2 Installing
– Before inserting speed sensor, clean hole inner surface and
coat speed sensor all-round with polycarbamide grease -G
052 142 A2- .
– Insert speed sensor into hole in wheel bearing housing and
tighten bolt to 8 Nm. swa
gen AG
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– Connect speed sensor to speed sensor
se
dwire.
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7.2 Removing and installing
ss
au parts of ABS system on rear axle ra
c

ce
e
nl

pt
du

an
1 - ABS speed sensor
itte

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erm

ab
❑ Before inserting sensor,

ility
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clean fitting hole inner

wit
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surface and coat with

h re
polycarbamide grease -
hole

spec
G 052 142 A2- .
es, in part or in w

t to the co
❑ Removing and installing
⇒ page 33
2 - Hexagon socket head bolt,
rrectness of i
8 Nm
l purpos

3 - Wheel hub with wheel bear‐

ing
nf
ercia

❑ ABS sensor ring is in‐

orm

stalled in the wheel

m

atio
m

bearing.
o

n in
or c

thi

4 - Drive shaft
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

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

 Touareg 2003 ➤
Brake systems - Edition 07.2009

7.3 Removing and installing speed sensor

on rear axle

7.3.1 Removing
– Raise vehicle.
– Separate connector -1- from speed sensor wire and from
speed sensor.
– Remove bolt -2- from wheel bearing housing.
– Pull ABS speed sensor out of wheel bearing housing.

n AG. Volkswagen AG do
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7.3.2 Installing ss

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

itte

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coat speed sensor all-round with polycarbamide grease -G
rm

ab
pe

052 142 A2- .

ility
ot

wit
, is n

– Insert speed sensor into hole in wheel bearing housing and

h re
tighten bolt to 8 Nm.
hole

spec
es, in part or in w

– Connect speed sensor to speed sensor wire.

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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rp

cum
fo

en
ng

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

7. Removing and installing parts of ABS system on front and rear axle 33
 Touareg 2003 ➤
Brake systems - Edition 07.2009

8 Removing and installing parts of ESP

system
AG. Volkswagen AG d
agen oes
olksw not
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8.1 Removing and installing ESP sensor by gu
d ara
rise nte
unit -G419- tho eo
au ra
ss c
The lateral acceleration sender -G200- , the yaw rate sender -

ce
le
un

pt
G202- and the longitudinal acceleration sender -G251- are in‐

an
d
itte

y li
stalled in a housing beneath the centre console.
rm

ab
pe

ility
After exchanging the ESP sensor unit -G419- , perform basic set‐
ot

wit
, is n

ting for lateral acceleration sender -G200- and the longitudinal

h re
acceleration sender -G251- .
hole

spec
es, in part or in w

t to the co
WARNING

Shocks or jolts can destroy the lateral acceleration sender -

rrectness of i
G200- , the yaw rate sensor -G202- and the longitudinal ac‐
celeration sender -G251- .
l purpos

nform
ercia

8.1.1 Removing
m

a
com

ti
– Remove centre console ⇒ General body repairs, interior; Rep.

on in
Gr. 68 ; Compartments, covers and trims; Removing and in‐
r
te o

thi
stalling centre console .

s
iva

do
r
rp

cum
fo

en
WARNING
ng

t.
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Cop py
t. rig
When working on the Airbag control unit -J234- , please follow
gh ht
yri by
the general safety procedures for working on the airbag, belt
cop Vo
by lksw
cted
tensioner and battery isolation units (pyrotechnical units) ⇒
agen
Prote AG.
General body repairs, interior; Rep. Gr. 69 .

– Disconnect battery ⇒ Electrical system; Rep. Gr. 27 ; Dis‐

connecting and reconnecting battery .
– Unscrew airbag control unit and move clear forwards ⇒ Gen‐
eral body repairs, interior; Rep. Gr. 69 ; Airbag; Removing and
installing airbag control unit (J234) .
– Pull connector -1- off ESP sensor unit -G419- .
– Remove the two securing nuts -arrows-.
– Remove ESP sensor unit -G419- .

8.1.2 Installing
– Install in reverse order.
When installing the ESP sensor unit, make sure it is correctly
seated in its bracket and is free of stress.

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

 Touareg 2003 ➤
Brake systems - Edition 07.2009

Do not use the securing nuts to forcibly position ESP sensor unit.
– Tighten securing nuts to 8 Nm.
– Carry out basic settings for lateral acceleration sender -G200-
and longitudinal acceleration sender -G251- .
Connecting -VAS 5051- and gselecting
en AG. V functions
olkswagen AG ⇒ page 11 .
d wa oes
olks not
8.2 Removing and installing steering angle
ed
byV gu
ara
nte
ris
sender -G85-
au
tho eo
ra
ss c
The steering angle sender -G85- is located between the steering

ce
le
un

pt
wheel and steering column switch.

an
d
itte

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rm

8.2.1 Removing and installing

ab
pe

ility
ot

wit
, is n

⇒ Electrical system; Rep. Gr. 94 ; Lights, bulbs, switches - ex‐

h re
terior; Steering column switch .
hole

spec
es, in part or in w

– Then perform basic setting of steering angle sender -G85- .

t to the co
Connecting -VAS 5051- and selecting functions ⇒ page 11 .

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

8. Removing and installing parts of ESP system 35

 Touareg 2003 ➤
Brake systems - Edition 07.2009

46 – Brakes -wamechanism
gen AG
. Volkswagen AG
doe
olks s no
yV t gu
db ara
1 Repairing front brakes
tho
ris
e nte
eo
au ra
c
ss

ce
e
nl

pt
1.1 Repairing front brakes, FN 3 brake cali‐
du

an
itte

y li
per (16")
erm

ab
ility
ot p

wit
, is n

h re
Note
hole

spec
es, in part or in w

t to the co
♦ Every time after changing pads, depress brake pedal firmly
several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.

rrectness of i
♦ After work for which the brake system had to be opened, bleed
the brake system with brake filling and bleeding unit -
l purpos

VAS 5234- or extraction unit -V.A.G 1869/4- .

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

nform
ercia

brake caliper or disconnecting a brake hose (release pressure

m

at
in system).
om

ion
c

in t
or

his
ate

do
riv

1 - Brake disc
p

cum
or

❑ Ventilated brake disc: ∅

f

en
ng

t.
yi
308 mm
Co
Cop py
ht. rig
❑ Brake disc thickness: py
rig by
ht
29.5 mm co Vo
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cted agen
❑ Wear limit: 25.5 mm Prote AG.

❑ Always renew on both

sides of an axle.
❑ Remove brake caliper
and brake carrier prior to
removing.
2 - Fitted bolt, 15 Nm
❑ Brake disc to wheel hub
3 - Brake pads
❑ Thickness: 11.5 mm
without backplate
❑ Pad wear limit: 2 mm
without backplate
❑ With break pad wear in‐
dicator
❑ When wear reaches a
predetermined limit (ap‐
prox. 4 mm) the warning
lamp in the dash panel
insert comes on.
❑ Checking thickness
⇒ Maintenance ; Book‐
let 17.1 ; Work sequen‐
ces; Front and rear
brake pads/linings:
Checking thickness .
❑ Always renew on both
sides of an axle.
❑ Removing and installing

36 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

⇒ page 37
4 - Retaining spring
❑ Press under brake carrier and insert into both holes in brake caliper housing.
5 - Brake caliper
❑ Do not disconnect brake hose when changing brake pads or brake discs.
❑ Removing and installing ⇒ page 41
❑ Repairing ⇒ page 114
6 - Guide pin, 30 Nm
7 - Cover cap
8 - Retainer for brake pad wear indicator line
9 - Bolt, 10 Nm
10 - Brake carrier
❑ Bolt to wheel bearing housing
11 - Hexagon bolt, 270 Nm
❑ Always renew after removing
12 - Bracket
13 - Hexagon socket head bolt, 9 Nm
14 - Brake hose, 14 Nm
❑ Do not unscrew when changing brake pads or brake discs. AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
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r
1.2 Removing and installing brake pads/lin‐ ho eo
aut ra
s c
ings s

ce
le
un

pt
an
d

Special tools and workshop equipment required

itte

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erm

ab
♦ Torque wrench -V.A.G 1331-

ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

♦ Piston resetting tool -T10145-

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

1. Repairing front brakes 37

 Touareg 2003 ➤
Brake systems - Edition 07.2009

1.2.1 Removing
Mark brake pads when removing if they are to be reused. Fit in
same position when installing, or braking will be uneven.
– Remove wheels.
– Press retaining spring in direction of -arrow A- until it can be
pressed out of hole in direction of -arrow B-.

– Turn retaining spring -1- clockwise -arrow- until it can be re‐

moved from the upper hole.

AG. Volkswagen AG d
agen oes
olksw not
– Disconnect connector -1- for brake dpad by wear indicator.
V gu
ara
ise nte
r
– Pull off dust cap -2- and lift offubrake
tho pad wear indicator wire. eo
ra
s a c
– Remove brake pad wear indicator wire from brake caliper
s
ce
e
nl

housing retainer -3-.

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

– Remove caps -arrows-.

rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

38 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Unscrew both guide pins -arrows- from brake caliper and re‐
move.
– Remove brake caliper and secure with wire so that weight of
brake caliper does not strain or damage brake hose.
– Remove brake pads.
Cleaning:

WARNING

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

– Thoroughly clean brake carrier and contact surfaces for brake

pads and remove corrosion. en AG. Volkswagen AG
ag does
lksw n
– Clean brake caliper (remove
db
yV
o
adhesive remains), the adhesive
ot g
ua
surface must be clean
o
ir se and dry.
ran
te
h eo
ut ra
Use only methylated
ss
a spirits for cleaning the brake caliper housing. c

ce
le
un

pt
1.2.2 Installing

an
d
itte

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rm

ab
pe

Before pressing piston back into cylinder with piston resetting tool,

ility
ot

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

wit
, is n

h re
ularly if reservoir has been topped up, fluid will overflow and cause
hole

damage.

spec
es, in part or in w

– Press pistons back with piston resetting tool -T10145- -1-.

t to the co
Note
rrectness of i
l purpos

The inner brake pad (piston side) is rotation sensitive and is

therefore marked.
nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
g

Directional brake pads

n

t.
yi Co
Cop py
1 - Right-hand piston side brake pad
t. rig
gh ht
pyri by
Vo
o
2 - Left-hand piston side brake pad
c by lksw
cted agen
Prote AG.
When installed, the arrow -A- on the brake pad backplate must
point downwards (in direction of brake disc rotation).

1. Repairing front brakes 39

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Insert brake pad with retaining spring into the piston

-arrows-.
– Pull protective foil off outer brake pad backplate.

– Fit outer brake pad -A- to brake carrier.

When positioning the brake caliper, ensure that the brake pad
does not stick to the brake caliper housing before it is positioned
correctly.

– Bolt brake caliper to brake carrier with both guide pins

-arrows-.
– Fit both cover caps. agen
AG. Volkswagen AG d
oes
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d by ara
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or eo
h
aut ra
ss c
ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec

– Reconnect brake wear indicator connector -1- to connector on

es, in part or in w

bracket on wheel bearing housing.

t to the co

– Secure the brake wear indicator wire with the dust cap -2- on
bleed valve and retainer -3- on brake caliper.
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

40 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Fit retaining spring into upper hole -arrow- and turn anti-clock‐
wise -direction of arrow-.
– Seat retaining spring into lower section of brake carrier.

– First press retaining spring in -direction of arrow A-, and then

simultaneously into hole in brake caliper
-direction of arrow B-.
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. Gr. 44 ; Specified torques of wheel
wage
bolts
n AG. V.olkswagen AG d
oe
ks s no
Vol t gu
d by ara
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ris
Note utho eo
ra
a c
ss
♦ Every time after changing pads, depress brake pedal firmly

ce
le
un

pt
several times with vehicle stationary, so that brake pads are

an
d
itte

y li
properly seated in their normal operating position.
rm

ab
pe

ility
♦ Check brake fluid level after changing brake pads.
ot

wit
, is n

h re
hole

Specified torque

spec
es, in part or in w

Brake caliper to brake carrier 30 Nm

t to the co

1.3 Removing and installing brake caliper

rrectness of i

Special tools and workshop equipment required

l purpos

♦ Torque wrench -V.A.G 1331-

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

1. Repairing front brakes 41

 Touareg 2003 ➤
Brake systems - Edition 07.2009

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

n AG. Volkswagen AG do
lkswage es n
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byV ua
d ran
ir se tee
tho
or
1.3.1 Removing ss
au ac

ce
e
nl

This procedure applies only to exchanging or the following repair

pt
du

an
work on the brake caliper.
itte

y li
erm

ab
– Remove wheels.

ility
ot p

wit
, is n

– Press retaining spring in direction of -arrow A- until it can be

h re
pressed out of hole in direction of -arrow B-.
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

– Turn retaining spring -1- clockwise -arrow- until it can be re‐

his
ate

moved from the upper hole.

do
priv

cum
for

en
ng

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

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

– Pull off dust cap -2- and lift off brake pad wear indicator wire.
– Remove brake pad wear indicator wire from brake caliper
housing retainer -3-.
– Connect bleeder bottle hose to brake caliper bleeder valve and
open bleeder valve.
– Apply brake pedal depressor -V.A.G 1869/2- .
– Close bleeder valve and remove bleeder bottle.
– Disconnect brake hose.

42 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Remove caps -arrows-.

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

ce
le
un

pt
an
d
itte

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erm

– Unscrew and remove both guide pins -arrows- from brake cal‐

ab
ility
iper.
ot p

wit
is n

– Pull brake caliper off brake carrier.

h re
ole,

spec
– Remove brake pads from brake caliper.
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
1.3.2 Installing
om

n
c

i
or

• Piston is pressed back. n thi

te

sd
iva

o
r

• Outer brake pad is seated on brake carrier.

p

cum
r
fo

en
ng

– Insert inner brake pad with retaining spring into brake caliper
t.
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op
(piston). C py
t. rig
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pyri by
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Note Prote AG.

The inner brake pad (piston side) is rotation sensitive and is

therefore marked.

Directional brake pads

1 - Right-hand piston side brake pad
2 - Left-hand piston side brake pad
When installed, the arrow -A- on the brake pad backplate must
point downwards (in direction of brake disc rotation).
When positioning the brake caliper, ensure that the brake pad
does not stick to the brake caliper housing before it is positioned
correctly.
Do not damage adhesive surface.
– Bolt brake caliper to brake carrier with both guide pins.
– Fit both cover caps.
– Bolt brake hose to brake caliper.
– Remove brake pedal depressor -V.A.G 1869/2- .

1. Repairing front brakes 43

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Fit retaining spring into upper hole -arrow- and turn anti-clock‐
wise -direction of arrow-.
– Seat retaining spring into lower section of brake carrier.

AG. Volkswagen AG d
agen oes
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byV gu
ara
ed
– First press retaining spring in -direction of horarrow
is A-, and then nte
eo
simultaneously into hole in brake calipers aut ra
c
-direction of arrow B-. s

ce
le
un

pt
– Bleed brake system ⇒ page 133 .

an
d
itte

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rm

ab
– Fit wheels.
pe

ility
ot

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

wit
, is n

h re
Rep. Gr. 44 ; Specified torques of wheel bolts .
hole

spec
es, in part or in w

t to the co
Note

♦ Firmly depress brake pedal several times with vehicle station‐

rrectness of i
ary, so that the brake pads are properly seated in their normal
operating position.
l purpos

♦ Check brake fluid level.

nform
ercia

Specified torques:
m

a
com

tio
Guide pin to brake carrier 30 Nm

n in
r
te o

thi
Brake hose to brake caliper 14 Nm
s
iva

do
r
rp

cum
fo

1.4 Repairing front brake, Brembo 17" brake

en
ng

t.
yi Co
op
caliper (1LC)
C py
ht. rig
rig ht
py by
Vo
Period of use: to week 32 of 2005
co lksw
by
cted agen
Prote AG.

Note

♦ Every time after changing pads, depress brake pedal firmly

several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
♦ After work for which the brake system had to be opened, bleed
the brake system with brake filling and bleeding unit -
VAS 5234- or extraction unit -V.A.G 1869/4- .
♦ Fit brake pedal depressor -V.A.G 1869/2- before removing a
brake caliper or disconnecting a brake hose (release pressure
in system).

44 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

1 - Brake disc
❑ Ventilated brake disc: ∅
330 mm
❑ Brake disc thickness: 32
mm
❑ Wear limit: 30 mm
❑ Always renew on both
sides of an axle.
❑ Different designs on left
and right.
❑ Unscrew brake caliper
prior to removing, do not
disconnect brake line
but remove bracket
⇒ Item 7 (page 45) .
2 - Fitted bolt, 15 Nm
❑ Brake disc to wheel hub
3 - Brake caliper AG. Volkswagen AG d
agen oes
ksw
❑ Do not disconnect brake by
Vol not
gu
ara
line when changing rised
nte
brake discs. ut
ho eo
ra
a c
❑ Removing and installing ss

ce
e

⇒ page 49
nl

pt
du

an
itte

❑ Repairing ⇒ page 117

y li
erm

ab
4 - Hexagon bolt, 270 Nm

ility
ot p

wit
, is n

❑ Always renew after re‐

h re
moving
hole

spec
es, in part or in w

5 - Brake line, 14 Nm

t to the co
❑ Do not disconnect brake
line when changing
brake discs.

rrectness of i
6 - Spring clip
l purpos

7 - Bracket

nf
ercia

❑ Bolt to wheel bearing housing

orm
m

8 - Hexagon socket head bolt, 9 Nm

atio
om

n in
c

9 - Brake hose
or

thi
te

❑ Ensure that lugs are properly seated in grooves in bracket.

sd
iva

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r
rp

cu

10 - Hexagon bolt, 30 Nm
o

m
f

en
ng

t.
yi Co
11 - Retaining pin t. Cop py
rig
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yri
12 - Retaining spring p by
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13 - Brake pads Prote AG.

❑ Thickness: 10 mm not including backplate

❑ Pad wear limit: 2 mm without backplate
❑ With break pad wear indicator
❑ When wear reaches a predetermined limit (approx. 4 mm) the warning lamp in the dash panel insert
comes on.
❑ Checking thickness ⇒ Maintenance ; Booklet 17.1 ; Work sequences; Front and rear brake pads/linings:
Checking thickness .
❑ Always renew on both sides of an axle.
❑ Removing and installing ⇒ page 46 .
14 - Brake pad wear indicator wire

1. Repairing front brakes 45

 Touareg 2003 ➤
Brake systems - Edition 07.2009

1.5 Removing and installing brake pads/lin‐

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

♦ Piston resetting tool -T10145-

AG. Volkswagen AG d
1.5.1 Removing Volksw
agen oes
not
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d by ara
Mark brake pads when removing if they orisare to be reused. Fit in
e nte
eo
same position when installing, or braking
aut
h
will be uneven. ra
ss c
– Remove wheels.
ce
e
nl

pt
du

an

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

itte

y li
erm

ab

– Pull off dust cap -2- and lift off brake pad wear indicator wire.
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

46 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Remove bolt.

AG. Volkswagen AG d
agen oes
olksw not
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d by ara
ise nte
or eo
h
aut ra
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ce
e
nl

pt
du

an
itte

y li
erm

– Press retaining spring inwards -arrow- whilst pulling out re‐

ab
ility
taining pin -1-.
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

– Pull brake pad wear indicator -arrows- wire out of brake caliper

at
om

io
housing and out of retaining spring -1-.

n
c

in t
or

his
e

– Remove retaining spring.

at

do
priv

c
Before pressing back brake pads, draw off brake fluid from res‐
um
for

en

ervoir. Otherwise, particularly if reservoir has been topped up,

ng

t.
yi Co
fluid will overflow and cause damage. t. Cop py
rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

– Push brake pads off brake disc and remove from brake caliper.
– If the brake pads are to be renewed, carefully remove sensor
with wire for brake pad wear indicator from the brake pads and
check for damage.
Sensors and wires which are not damaged can be used again.
Cleaning:

WARNING

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

– Clean brake caliper.

Use only methylated spirits for cleaning the brake caliper housing.

1.5.2 Installing
Before pressing piston back into cylinder with piston resetting tool,
draw off brake fluid from brake fluid reservoir. Otherwise, partic‐

1. Repairing front brakes 47

 Touareg 2003 ➤
Brake systems - Edition 07.2009

ularly if reservoir has been topped up, fluid will overflow and cause
damage.
. Volkswagen AG
– Press pistons back.kswagen AG does
not
Vol gu
– Carefully insert by
ed the sensors of the wire for the brakearpad
an wear
ris
indicator uinto
th the new brake pads.
o tee
or
a ac
ss
– Insert brake pads into brake caliper.

ce
e
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Fit retaining spring -1-.

nf
ercia

– Insert brake wear indicator wire under the retainer in the re‐

orm
taining spring and into brake caliper housing -arrows-.
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

– Press retaining spring inwards -arrow- and drive retaining pin

-1- in onto limit stop.
Ensure that the flat edge of the retaining pin seats correctly into
brake caliper housing (preventing it from turning).

– Tighten bolt.

48 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Reconnect brake wear indicator connector -1- to connector on

bracket on wheel bearing housing.
– Secure brake wear indicator wire on bleed valve with the dust
cap -2-.
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. Gr. 44 ; Specified torques of wheel bolts .

Note n AG. Volkswagen AG do

lkswage es n
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♦ Every time after changing pads, depress brake ir se
dpedal firmly
b ua
ran
several times with vehicle stationary, so thatth brake pads are
o tee
or
properly seated in their normal operatingssposition.
au ac

ce
le
♦ Check brake fluid level after changing brake pads.
un

pt
an
d
itte

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erm

ab
Specified torque

ility
ot p

Hexagon bolt to retaining pin 30 Nm

wit
is n

h re
ole,

spec
1.6 Removing and installing brake caliper
urposes, in part or in wh

t to the co
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1410-

rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
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Cop py
t. rig
gh ht
pyri by
♦ Torque wrench -V.A.G 1576-
co Vo
by lksw
cted agen
Prote AG.

1. Repairing front brakes 49

 Touareg 2003 ➤
Brake systems - Edition 07.2009

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

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

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

1.6.1 Removing

t to the co
This procedure applies only to exchanging or the following repair
work on the brake caliper.

rrectness of i
– Remove wheels.
l purpos

– Connect bleeder bottle hose to a bleeder valve on brake cali‐

per and open bleeder valve.

nf
ercia

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

m
m

atio
m

– Close bleeder valve and remove bleeder bottle.

o

n in
or c

thi
e

– Disconnect brake line from brake caliper.

t

sd
iva

o
r
rp

cu
– Disconnect bracket ⇒ Item 7 (page 45) from wheel bearing
o

m
f

housing.

en
ng

t.
yi Co
op py
– Remove brake pads ⇒ page 46 . t. C rig
gh ht
pyri by
– Unbolt brake caliper from wheel bearing housing.
o Vo
by c lksw
cted agen
Prote AG.
1.6.2 Installing
– Bolt brake caliper to wheel bearing housing.
– Install brake pads ⇒ page 46 .
– Reconnect brake line to brake caliper.
– Bolt bracket ⇒ Item 7 (page 45) to wheel bearing housing.
– Remove brake pedal depressor -V.A.G 1869/2- .
– Bleed brake system ⇒ page 133 .
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. Gr. 44 ; Specified torques of wheel bolts .

Note

♦ Firmly depress brake pedal several times with vehicle station‐

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

Specified torques:
Hexagon bolt to wheel bearing housing 270 Nm
♦ Use new bolts!

Brake line to brake caliper 14 Nm

Bolt for bracket to wheel bearing housing. 9 Nm

50 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

1.7 Repairing front brake, Brembo 17" brake

caliper (1LE)
Period of use: from week 32 of 2005

Note

♦ Every time after changing pads, depress brake pedal firmly

several times with vehicle stationary, so that brake pads are
n AG. Volkswagen AG do
properly seated in their normal operatinglksposition.
wage es n
o Vo t gu
by
♦ After work for which the brake system
ris
ed had to be opened, bleed
ara
nte
the brake system with brake filling
tho and bleeding unit - eo
au
VAS 5234- or extraction unitss -V.A.G 1869/4- .
ra
c

ce
e

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

nl

pt
du

an
brake caliper or disconnecting a brake hose (release pressure
itte

y li
in system).
erm

ab
ility
ot p

wit
, is n

h re
hole

1 - Brake disc

spec
es, in part or in w

❑ Ventilated brake disc: ∅

t to the co
330 mm
❑ Brake disc thickness: 32
mm

rrectness of i
❑ Wear limit: 30 mm
l purpos

❑ Always renew on both

sides of an axle.

nf
ercia

❑ Different designs on left

orm
and right.
m

atio
m

❑ Unscrew brake caliper

o

n in
or c

prior to removing, do not

thi
te

disconnect brake line sd

iva

o
r

but remove bracket

rp

cu
o

⇒ Item 7 (page 51) .

f

en
ng

t.
yi Co
op
2 - Fitted bolt, 15 Nm C py
ht. rig
rig ht
❑ Brake disc to wheel hub py by
co Vo
by lksw
cted agen
3 - Brake caliper Prote AG.

❑ Do not disconnect brake

line when changing
brake discs.
❑ Removing and installing
⇒ page 54
❑ Repairing ⇒ page 117
4 - Hexagon bolt, 270 Nm
❑ Always renew after re‐
moving
5 - Brake line, 14 Nm
❑ Do not disconnect brake
line when changing
brake discs.
6 - Spring clip
7 - Retainer
❑ Bolt to wheel bearing housing

1. Repairing front brakes 51

 Touareg 2003 ➤
Brake systems - Edition 07.2009

8 - Hexagon socket head bolt, 9 Nm

9 - Brake hose
❑ Ensure that lugs are properly seated in grooves in bracket.
10 - Pad retaining pins
11 - Retaining spring
12 - Brake pads
❑ Thickness: 11 mm without backplate
❑ Pad wear limit: 2 mm without backplate
❑ With break pad wear indicator AG. Volkswagen AG d
agen
❑ When wear reaches a predetermined limit (approx. Volk4
swmm) the warning lampoein
s nothe dash panel insert
t gu
comes on. d by ara
rise nte
❑ Checking thickness ⇒ Maintenance ; Booklet
ut
ho 17.1 ; Work sequences; Front and rear brake e o pads/linings:
ra
Checking thickness . ss a c

ce
e

❑ Always renew on both sides of an axle.

nl

pt
du

an
itte

❑ Removing and installing ⇒ page 52

y li
erm

ab
13 - Brake pad wear indicator wire

ility
ot p

wit
, is n

h re
hole

spec
1.8 Removing and installing brake pads/lin‐
es, in part or in w

t to the co
ings
Special tools and workshop equipment required

rrectness of i
♦ Piston resetting tool -T10145-
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1.8.1 Removing
Mark brake pads when removing if they are to be reused. Fit in
same position when installing, or braking will be uneven.
– Remove wheels.
– Disconnect connector -1- for brake pad wear indicator.
– Pull off dust cap -2- and lift off brake pad wear indicator wire.

52 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Drive out brake pad retaining pins -arrows-.

– Pull brake pad wear indicator -arrows- wire out of brake caliper
housing and out of retaining spring -1-.
– Remove retaining spring.
Before pressing back brake pads, draw off brake fluid from res‐
ervoir. Otherwise, particularly if reservoir has been topped up,
fluid will overflow and cause damage.

– Push brake pads off brake disc and remove from brake caliper.
olkswagen AG
en AG. V
– If the brake pads are to be renewed, carefully removeolksensor
swa
g does
not
with wire for brake pad wear indicator from the brake
ed
b pads and
y V gu
ara
check for damage. ho
ris nte
eo
t
au ra
Sensors and wires which are not damaged can
ss be used again. c

ce
e
nl

pt
Cleaning:
du

an
itte

y li
erm

ab
ility
WARNING
ot p

wit
, is n

h re
Do not blow out brake system with compressed air; the result‐
hole

spec
ing dust constitutes a health hazard!
es, in part or in w

t to the co
– Clean brake caliper.
rrectness of i

Use only methylated spirits for cleaning the brake caliper housing.
l purpos

1.8.2 Installing
nf
ercia

Before pressing piston back into cylinder with piston resetting tool,
orm

draw off brake fluid from brake fluid reservoir. Otherwise, partic‐
m

atio
m

ularly if reservoir has been topped up, fluid will overflow and cause
o

n in
c

damage.
or

thi
te

sd
a

– Press pistons back.

iv

o
r
rp

cu
o

– Carefully insert the sensors of the wire for the brake pad wear
f

en
ng

t.
yi
indicator into the new brake pads.
Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1. Repairing front brakes 53

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Insert brake pads into brake caliper.

– Fit retaining spring -1-.

– Insert brake wear indicator wire under the retainer in the re‐
taining spring and into brake caliper housing -arrows-.
– Press retaining spring down and insert brake pad retaining
pins in brake caliper.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
– Drive brake pad retaining pins into brake caliper to stop. ss c
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Reconnect brake wear indicator connector -1- to connector on

bracket on wheel bearing housing.
nf
ercia

or

– Secure brake wear indicator wire on bleed valve with the dust
m
m

atio

cap -2-.
om

n in
or c

– Fit wheels.
thi
te

sd
iva

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

o
r
rp

cu

Rep. Gr. 44 ; Specified torques of wheel bolts .

o

m
f

en
ng

t.
yi Co
Cop py
t. rig
gh
Note
ht
pyri by
Vo
co lksw
by
cted agen
Prote
♦ Every time after changing pads, depress brake pedal firmly
AG.

several times with vehicle stationary, so that brake pads are

properly seated in their normal operating position.
♦ Check brake fluid level after changing brake pads.

1.9 Removing and installing brake caliper

Special tools and workshop equipment required

54 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

♦ Torque wrench -V.A.G 1410-

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

ce
le
un

pt
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d
itte

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erm

ab
ility
ot p

wit
is n

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ole,

spec
urposes, in part or in wh

t to the co
♦ Torque wrench -V.A.G 1576-

rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
op py
♦ Brake pedal depressor -V.A.G 1869/2-
t. C rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

1.9.1 Removing
This procedure applies only to exchanging or the following repair
work on the brake caliper.
– Remove wheels.
– Connect bleeder bottle hose to a bleeder valve on brake cali‐
per and open bleeder valve.
– Apply brake pedal depressor -V.A.G 1869/2- .
– Close bleeder valve and remove bleeder bottle.
– Disconnect brake line from brake caliper.
– Disconnect bracket ⇒ Item 7 (page 51) from wheel bearing
housing.
– Remove brake pads ⇒ page 52 .
– Unbolt brake caliper from wheel bearing housing.

1.9.2 Installing
– Bolt brake caliper to wheel bearing housing.

1. Repairing front brakes 55

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Install brake pads.

– Reconnect brake line to brake caliper.
– Bolt bracket ⇒ Item 7 (page 51) to wheel bearing housing.
– Remove brake pedal depressor -V.A.G 1869/2- .
– Bleed brake system ⇒ page 133 .
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. Gr. 44 ; Specified torques of wheel bolts .

Note

♦ Firmly depress brake pedal several times with vehicle station‐

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

Specified torques:
Hexagon bolt to wheel bearing housing 270 Nm
♦ Use new bolts!

Brake line to brake caliper 14 Nm

Bolt for bracket to wheel bearing housing. 9 Nm

1.10 Repairing front brake, Brembo 18" brake

caliper
AG. Volkswagen AG d
agen oes
olksw not
V gu
Note d by ara
rise nte
tho eo
u ra
♦ Every time after schanging
sa pads, depress brake pedal firmly c
several times with vehicle stationary, so that brake pads are
ce
le
un

pt

properly seated in their normal operating position.

an
d
itte

y li

♦ After work for which the brake system had to be opened, bleed
rm

ab
pe

ility

the brake system with brake filling and bleeding unit -

ot

VAS 5234- or extraction unit -V.A.G 1869/4- .

wit
, is n

h re
hole

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

spec

brake caliper or disconnecting a brake hose (release pressure

es, in part or in w

in system).
t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

56 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

1 - Brake disc
❑ Ventilated brake disc: ∅
350 mm
❑ Brake disc thickness: 34
mm
❑ Wear limit: 32 mm
❑ Always renew on both
sides of an axle. agen
AG. Volkswagen AG d
oes
lksw not
❑ Different designs on left d by
Vo gu
ara
and right. orise nte
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❑ Unscrew brake caliper aut ra
s c
prior to removing, do not s

ce
le
disconnect brake line

un

pt
an
d
but remove bracket itte

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⇒ Item 7 (page 57) .
rm

ab
pe

ility
ot

2 - Fitted bolt, 15 Nm

wit
, is n

h re
❑ Brake disc to wheel hub
hole

spec
3 - Brake caliper
es, in part or in w

t to the co
❑ Do not disconnect brake
line when changing
brake discs.

rrectness of i
❑ Removing and installing
l purpos

⇒ page 61
❑ Repairing ⇒ page 117

nform
ercia

4 - Hexagon bolt, 270 Nm

m

a
❑ Always renew after re‐
com

tio
moving

n in
r
te o

thi
5 - Brake line, 14 Nm

s
iva

do
r
rp

c
❑ Do not disconnect brake

um
fo

line when changing

en
ng

t.
yi
brake discs.
Co
Cop py
t. rig
gh
6 - Spring clip
ht
pyri by
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cted
7 - Retainer
agen
Prote AG.

❑ Bolt to wheel bearing housing

8 - Hexagon socket head bolt, 9 Nm
9 - Brake hose
❑ Ensure that lugs are properly seated in grooves in bracket.
10 - Hexagon bolt, 30 Nm
11 - Retaining pin
12 - Retaining spring
13 - Brake pads
❑ Thickness: 10 mm not including backplate
❑ Pad wear limit: 2 mm without backplate
❑ With break pad wear indicator
❑ When wear reaches a predetermined limit (approx. 4 mm) the warning lamp in the dash panel insert
comes on.
❑ Checking thickness ⇒ Maintenance ; Booklet 17.1 ; Work sequences; Front and rear brake pads/linings:
Checking thickness .
❑ Always renew on both sides of an axle.
❑ Removing and installing ⇒ page 58
14 - Brake pad wear indicator wire

1. Repairing front brakes 57

 Touareg 2003 ➤
Brake systems - Edition 07.2009

1.11 Removing and installing brake pads/lin‐

AG. Volkswagen AG d
agen
ings by Vol
ksw oes
not
gu
ara
ed nte
Special tools and workshop
tho
equipment
ris required e or
au ac
♦ Torque wrench -V.A.G
ss 1331-

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness
♦ Piston resetting tool -T10145-

o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

1.11.1 Removing
Mark brake pads/linings when removing if they are to be reused.
Fit in same position when installing, or braking will be uneven.
– Remove wheels.
– Disconnect connector -1- for brake pad wear indicator.
– Pull off dust cap -2- and lift off brake pad wear indicator wire.

58 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Remove bolt.

– Press retaining spring inwards -arrow- whilst pulling out re‐

taining pin -1-.

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lkswage es n
o ot g
byV ua
d ran
ir se
– Pull brake
tho pad wear indicator -arrows- wire out of brake tee
or caliper
housing
ss
au
and out of retaining spring -1-. ac
ce
le

– Remove retaining spring.

un

pt
an
d
itte

y li

Before pressing back brake pads, draw off brake fluid from res‐
rm

ab

ervoir. Otherwise, particularly if reservoir has been topped up,

pe

ility

fluid will overflow and cause damage.

ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

– Push brake pads off brake disc and remove from brake caliper.
l purpos

– If the brake pads are to be renewed, carefully remove sensor

with wire for brake pad wear indicator from the brake pads and
nform
ercia

check for damage.

m

a
com

Sensors and wires which are not damaged can be used again.
ion in
r
te o

Cleaning:
thi
s
iva

do
r
rp

cum
fo

WARNING
en
ng

t.
yi Co
op py
Do not blow out brake system with compressed air; the result‐
t. C rig
gh ht
ing dust constitutes a health hazard!
pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Clean brake caliper.

Use only methylated spirits for cleaning the brake caliper housing.

1.11.2 Installing
Before pressing piston back into cylinder with piston resetting tool,
draw off brake fluid from brake fluid reservoir. Otherwise, partic‐

1. Repairing front brakes 59

 Touareg 2003 ➤
Brake systems - Edition 07.2009

ularly if reservoir has been topped up, fluid will overflow and cause
damage.
– Press pistons back.
– Carefully insert the sensors of the wire for the brake pad wear
indicator into the new brake pads.
– Insert brake pads into brake caliper.

– Fit retaining spring -1-.

– Insert brake wear indicator wire under the retainer in the re‐
AG. Volkswagen AG d
taining spring and into brake caliper housing
lksw
agen-arrows-. oes
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yV ua
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ris tee
tho or
au ac
ss

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nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec

– Press retaining spring inwards -arrow- and drive retaining pin

es, in part or in w

t to the co

-1- in onto limit stop.

Ensure that the flat edge of the retaining pin seats correctly into
brake caliper housing (preventing it from turning).
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
or

– Tighten bolt.
f

en
ng

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

60 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Reconnect brake wear indicator connector -1- to connector on

bracket on wheel bearing housing.
– Secure brake wear indicator wire on bleed valve with the dust
cap -2-.
– Fit wheels.
n AG. Volkswagen AG do
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Specified torque of wheel bolts ⇒ y V Running gear, axles, steering;t gua
olk o
Rep. Gr. 44 ; Specified torques
ir se of wheel bolts .
d b ran
tee
tho or
au ac
ss
Note

ce
le
un

pt
an
d
itte

y li
♦ Every time after changing pads, depress brake pedal firmly
erm

ab
several times with vehicle stationary, so that brake pads are

ility
ot p

properly seated in their normal operating position.

wit
is n

h re
♦ Check brake fluid level after changing brake pads.
ole,

spec
urposes, in part or in wh

t to the co
Specified torque
Hexagon bolt to retaining pin 30 Nm

rrectne
1.12 Removing and installing brake caliper

ss o
Special tools and workshop equipment required
cial p

f inform
♦ Torque wrench -V.A.G 1410-
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

♦ Torque wrench -V.A.G 1576-

1. Repairing front brakes 61

 AG. Volkswagen AG d
agen oes
ksw not
Touareg 2003 ➤ by Vol
gu
ara
d
Brake systems - Edition 07.2009 orise nte
eo
th
au ra
s c
♦ Brake pedal depressor -V.A.G 1869/2- s

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

1.12.1 Removing

nform
ercia

This procedure applies only to exchanging or the following repair

m

at
om

work on the brake caliper.

ion
c

in t
or

– Remove wheels.

his
ate

do
riv

– Connect bleeder bottle hose to a bleeder valve on brake cali‐

p

cum
or

per and open bleeder valve.

f

en
ng

t.
yi Co
– Apply brake pedal depressor -V.A.G 1869/2- . Cop py
t. rig
gh ht
yri
– Close bleeder valve and remove bleeder bottle.
p by
co Vo
by lksw
cted agen
– Disconnect brake line from brake caliper.
Prote AG.

– Disconnect bracket ⇒ Item 7 (page 57) from wheel bearing

housing.
– Remove brake pads ⇒ page 58 .
– Unbolt brake caliper from wheel bearing housing.

1.12.2 Installing
– Bolt brake caliper to wheel bearing housing.
– Install brake pads ⇒ page 58 .
– Reconnect brake line to brake caliper.
– Bolt bracket ⇒ Item 7 (page 57) to wheel bearing housing.
– Remove brake pedal depressor -V.A.G 1869/2- .
– Bleed brake system ⇒ page 133 .
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. Gr. 44 ; Specified torques of wheel bolts .

Note

♦ Firmly depress brake pedal several times with vehicle station‐

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

Specified torques:
Hexagon bolt to wheel bearing housing 270 Nm
♦ Use new bolts!

Brake line to brake caliper 14 Nm

Bolt for bracket to wheel bearing housing. 9 Nm

62 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

1.13 Repairing front brake, Brembo 18" brake

caliper Plus

Note

♦ Every time after changing pads, depress brake pedal firmly

several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
♦ After work for which the brake system had to be opened, bleed
the brake system with brake filling and bleeding unit - gen AG. Volkswagen AG d
VAS 5234- or extraction unit -V.A.G 1869/4- . Volkswa oes
not
y gu
db ara
♦ Fit brake pedal depressor -V.A.G 1869/2- before
or
ise removing a nte
brake caliper or disconnecting a brake hose
au (release pressure
th eo
ra
in system). ss c

ce
le
un

pt
an
d
itte

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erm

ab
1 - Brake disc

ility
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❑ Ventilated brake disc: ∅

wit
is n

368 mm

h re
ole,

❑ Brake disc thickness: 36

spec
urposes, in part or in wh

mm

t to the co
❑ Wear limit: 34 mm
❑ Always renew on both

rrectne
sides of an axle.
❑ Different designs on left

s
and right.

s o
cial p

f
❑ For removal, first unbolt

inform
brake caliper. Do not
mer

disconnect brake hose.

atio
om

n
2 - Fitted bolt, 15 Nm
c

i
or

n thi
e

❑ Brake disc to wheel hub

t

sd
iva

o
pr

c
3 - Brake pad wear indicator
um
r
fo

en
ng

wire
t.
yi Co
op py
4 - Brake caliper
t. C rig
gh ht
yri by
❑ Do not disconnect brake cop Vo
by lksw
hose when changing
cted agen
Prote AG.
brake pads or brake
disc.
❑ Removing and installing
⇒ page 66
❑ Repairing ⇒ page 117
5 - Hexagon bolt, 270 Nm
❑ Always renew after re‐
moving
6 - Retaining spring
❑ For brake pads
7 - Retaining spring
❑ For brake pad wear in‐
dicator wire
8 - Brake pads
❑ Thickness: 10 mm not including backplate
❑ Wear limit: 2 mm not including backplate
❑ With break pad wear indicator

1. Repairing front brakes 63

 Touareg 2003 ➤
Brake systems - Edition 07.2009
❑ When wear reaches a predetermined limit (approx. 4 mm) the warning lamp in the dash panel insert
comes on.
❑ Checking thickness ⇒ Maintenance ; Booklet 17.1 ; Work sequences; Front and rear brake pads/linings:
Checking thickness .
❑ Always renew on both sides of an axle.
❑ Removing and installing ⇒ page 64
9 - Clip
❑ For brake pad wear indicator wire
10 - Brake hose, 14 Nm
11 - Hexagon bolt, 20 Nm
12 - Bracket
❑ Bolt to wheel bearing housing

1.14 Removing and installing brake pads/lin‐

ings
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1576-

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

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
♦ Piston resetting tool -T10145-
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi

1.14.1 Removing
s
iva

do
r
rp

cum

Mark brake pads/linings when removing if they are to be reused.

fo

en
ng

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

t.
yi Co
Cop py
.
– Remove wheels.
ht rig
rig ht
py by
co Vo
– Separate connector for brake pad wear indicator.
by lksw
cted agen
Prote AG.
– Remove brake pad wear indicator wire from clip and take it out
of retaining spring.
– Pull brake hose out of retainer on wheel bearing housing.

64 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

Before pressing back brake pads, draw off brake fluid from res‐
ervoir. Otherwise, particularly if reservoir has been topped up,
fluid will overflow and cause damage.
– Push brake pads off brake disc.
– Carefully remove sensor with brake pad wear indicator wire
from brake pads and check for damage.
Sensors and wires which are not damaged can be used again.
– Unbolt brake caliper -arrows- from wheel bearing housing.

Caution

Never unbolt brake caliper from adapter plate. Do not loosen

radially bolted multipoint bolts.

– Remove brake caliper and secure with wire so that weight of

brake caliper does not strain or damage brake hose.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

– Lever brake pads with a commercially available screwdriver

wit
is n

out of brake caliper -arrows-, being careful not to damage dust

h re

caps.
ole,

spec
urposes, in part or in wh

– Take brake pads out of retaining springs.

t to the co

Cleaning:
rrectne

WARNING
s

Do not blow out brake system with compressed air; the result‐
s o
cial p

ing dust constitutes a health hazard!

inform
mer

atio
m

– Clean brake caliper.

o

n
c

i
or

n thi

Use only methylated spirits for cleaning the brake caliper housing.
te

sd
iva

o
pr

cum
r
fo

1.14.2 Installing
en
ng

t.
yi Co
op py
Before pressing piston back into cylinder with piston resetting tool,
t. C rig
gh ht
yri
draw off brake fluid from brake fluid reservoir. Otherwise, partic‐
p by
co Vo
ularly if reservoir has been topped up, fluid will overflow and cause
by lksw
cted agen
Prote
damage.
AG.

– Press pistons back.

• The retaining springs are correctly seated in the brake caliper.
• The long part of the retaining springs faces towards the middle
of the brake caliper.
– Pull protective foil off brake pad backplate.

1. Repairing front brakes 65

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Insert brake pads into brake caliper and push onto 4 pad re‐
taining pins -arrows-.

WARNING

The brake pads must be correctly seated in the brake pad re‐
taining springs and on the retaining pins.

– Set brake pads onto 4 contact surfaces of brake pad retaining

springs -arrows-.
– Carefully set brake caliper over brake disc.
n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
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ir se tee
tho
u or
a ac
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

– Bolt brake caliper -arrows- to wheel bearing housing.

spec
es, in part or in w

t to the co
– Push brake hose into retainer on wheel bearing housing.
– Carefully insert sensors of brake pad wear indicator wire into
new brake pads.

rrectness of i
– Insert brake pad wear indicator wire under retainers in retain‐
l purpos

ing spring and into clip.

– Reconnect connector for brake pad wear indicator.
nform
ercia

– Fit wheels.
m

at
om

io

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

n
c

in t
or

Rep. Gr. 44 ; Specified torques of wheel bolts .

his
ate

do
priv

cum
for

Note
en
ng

t.
yi Co
Cop py
t. rig
♦ Every time after changing pads, depress brake pedal firmly gh ht
yri by
several times with vehicle stationary, so that brake pads are cop Vo
by lksw
properly seated in their normal operating position.
cted agen
Prote AG.

♦ Check brake fluid level after changing brake pads.

Specified torques:
Hexagon bolt to wheel bearing housing 270 Nm
♦ Use new bolts!

1.15 Removing and installing brake caliper

Special tools and workshop equipment required

66 Rep. Gr.46 - Brakes - mechanism

 AG. Volkswagen AG d
agen oes
olksw not
V
d by gu
ara Touareg 2003 ➤
ise nte
thor Brake systemse or - Edition 07.2009
s au ac
s
♦ Torque wrench -V.A.G 1576-

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f
♦ Brake pedal depressor -V.A.G 1869/2-

inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

1.15.1 Removing
This procedure applies only to exchanging or the following repair
work on the brake caliper.
– Remove wheels.
– Connect bleeder bottle hose to a bleeder valve on brake cali‐
per and open bleeder valve.
– Apply brake pedal depressor -V.A.G 1869/2- .
– Close bleeder valve and remove bleeder bottle.
– Separate connector for brake pad wear indicator.
– Disconnect brake hose from brake caliper.
– Unbolt brake caliper from wheel bearing housing.
– Remove brake pads ⇒ page 64 .

1.15.2 Installing
– Install brake pads ⇒ page 64 .
– Bolt brake caliper to wheel bearing housing.
– Reconnect brake hose to brake caliper.
– Carefully insert sensors of brake pad wear indicator wire into
new brake pads.
– Insert brake pad wear indicator wire under retainers in retain‐
ing spring and into clip.
– Reconnect connector for brake pad wear indicator.
– Remove brake pedal depressor -V.A.G 1869/2- .
– Bleed brake system ⇒ page 133 .
– Fit wheels.

1. Repairing front brakes 67

 Touareg 2003 ➤
Brake systems - Edition 07.2009

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

Rep. Gr. 44 ; Specified torques of wheel bolts .

Note

♦ Firmly depress brake pedal several times with vehicle station‐

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

Specified torques:
Hexagon bolt to wheel bearing housing 270 Nm
♦

Brake hose to brake caliper 14 Nm

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

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

68 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

2 Repairing rear brakes

2.1 Repairing rear brakes, brake caliper FN

44

Note

♦ Every time after changing pads, depress brake pedal firmly

several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
♦ After work for which the brake system had to be opened, bleed
the brake system with brake filling and bleeding unit -
VAS 5234- or extraction unit -V.A.G 1869/4- .
♦ Fit brake pedal depressor -V.A.G 1869/2- before removing a
brake caliper or disconnecting a brake hose (release pressure
in system).
AG. Volkswagen AG d
agen oes
olksw not
yV gu
1 - Brake disc/drum ised b ara
nte
or
❑ Ventilated aut brake disc: ∅
h eo
ra
314 mmss c
ce
e

❑ Brake disc thickness: 22

nl

pt
du

an

mm
itte

y li
erm

ab

❑ Wear limit: 18 mm
ility
ot p

❑ Brake drum: ∅ 185 mm.

wit
, is n

h re

❑ Pad wear limit: 186 mm

hole

spec

❑ Always renew on both

es, in part or in w

sides of an axle.
t to the co

❑ Remove brake caliper

and brake carrier prior to
rrectness of i

removing but to not

open brake line.
l purpos

2 - Fitted bolt, 20 Nm
❑ Brake disc to wheel hub
nform
ercia

3 - Brake carrier
m

at
om

io

❑ Bolt to wheel bearing

n
c

in t
or

housing
his
ate

do
riv

4 - Hexagon bolt, 200 Nm

p

cum
for

en
g

5 - Brake pads
n

t.
yi Co
op
❑ Thickness: 13 mm with‐
C py
ht. rig
out backplate
rig ht
py by
co Vo
by lksw
❑ Pad wear limit: 2 mm Prote
cted AG.
agen
without backplate
❑ With break pad wear in‐
dicator
❑ When wear reaches a
predetermined limit (ap‐
prox. 4 mm) the warning
lamp in the dash panel
insert comes on.
❑ Checking thickness
⇒ Maintenance ; Booklet 17.1 ; Work sequences; Front and rear brake pads/linings: Checking thickness .
❑ Always renew on both sides of an axle.

2. Repairing rear brakes 69

 Touareg 2003 ➤
Brake systems - Edition 07.2009
AG. Volkswagen AG d
❑ Removing and installing ⇒ pagelk70
swa
gen oes
not
o
yV gu
6 - Retaining spring risedb ara
nte
ho eo
7 - Brake caliper aut ra
ss c
❑ Do not disconnect brake hose when changing brake pads or brake discs.

ce
e
nl

pt
du

an
❑ Removing and installing ⇒ page 75
itte

y li
erm

ab
❑ Repairing ⇒ page 123

ility
ot p

8 - Secures brake pad wear indicator wiring.

wit
, is n

h re
hole

9 - Bolt, 10 Nm

spec
es, in part or in w

10 - Guide pin, 30 Nm

t to the co
11 - Cover cap
12 - Hexagon socket head bolt, 8 Nm

rrectness of i
13 - Retainer
l purpos

14 - Brake hose with banjo union and banjo bolt, 38 Nm

nform
ercia

❑ Do not unscrew when changing brake pads or brake discs.

m

at
15 - Hold-down pin
om

ion
c

in t
r

16 - Compression spring
o

his
ate

do
riv

17 - Extension spring
p

cum
or

❑ Fitting location: on the adjustment nut.

f

en
ng

t.
yi Co
❑ Identifying the spring ⇒ Item 18 (page 70) t. Cop py
rig
gh ht
yri
♦ larger number of spring coils p by
co Vo
by lksw
cted agen
♦ can be bent easily by hand Prote AG.

18 - Extension spring
❑ Fitting location: on expander
❑ Identifying the spring ⇒ Item 17 (page 70)
♦ smaller number of spring coils
♦ cannot be bent easily by hand
19 - Brake shoe
❑ Removing and installing ⇒ page 86
❑ Minimal thickness of brake lining: 1 mm
❑ Check thickness.
20 - Expander
21 - Adjustment nut
❑ Adjusting parking brake ⇒ page 101 .
22 - Brake backplate
23 - Rear brake cable

2.2 Removing and installing brake pads/lin‐

ings
Special tools and workshop equipment required

70 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

♦ Torque wrench -V.A.G 1331-

♦ Piston resetting tool -T10145-

2.2.1 Removing
Mark brake pads when removing if they are to be reused. Fit in
. Volkswage G
same position when installing,
swa
gen AGor brakingn A willdobe
es uneven.
olk not
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– Remove wheels.
ise
db ara
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r
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– Presssretaining
au
t
spring in -direction of arrow A- until it canr a be
c
pressed
s out of hole in -direction of arrow B-.
ce
le
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pt
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pe

ility
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hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Turn retaining spring -1- clockwise -arrow- until it can be re‐

moved from the upper hole.
nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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cum
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ng

t.
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Cop py
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pyri by
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by
cted agen
Prote AG.

2. Repairing rear brakes 71

 Touareg 2003 ➤
Brake systems - Edition 07.2009

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

– Remove brake pad wear indicator wire from brake caliper
housing retainer -2-.
– Remove brake wear indicator lower connector -3- and speed
sensor wire -4- from bracket on brake caliper.

– Remove caps -arrows-.

– Unscrew both guide pins -arrows- from brake caliper and re‐
n AG. Volkswagen AG do
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– Remove brake ris caliper and secure with wire so that weight
ed ran
tee of
brake caliper
utho does not strain or damage brake hose. or
a ac
ss
– Remove brake pads.
ce
le
un

pt
an
d

Cleaning:
itte

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ab
ility
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WARNING
wit
is n

h re
ole,

Do not blow out brake system with compressed air; the result‐
spec
urposes, in part or in wh

ing dust constitutes a health hazard!

t to the co

– Thoroughly clean brake carrier and contact surfaces for brake

rrectne

pads and remove corrosion.

– Clean brake caliper.
ss o

Use only methylated spirits for cleaning the brake caliper housing.
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

cum
r
fo

en
ng

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

72 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

2.2.2 Installing
Before pressing piston back into cylinder with piston resetting tool,
draw off brake fluid from brake fluid reservoir. Otherwise, partic‐
ularly if reservoir has been topped up, fluid will overflow and cause
damage.
– Press pistons back with piston resetting tool -T10145- .

Note agen
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The inner brake pad (piston side) is rotation risesensitive
d and is ara
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therefore marked. ut
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itte

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ab
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Directional brake pads

spec
es, in part or in w

When installed, the arrow -A- on the brake pad backplate must

t to the co
point downwards (in direction of brake disc rotation).

rrectness of i
l purpos

nform
mercia

a
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tion in
r
te o

thi
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t.
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cted agen
Prote AG.

– Insert brake pad with retaining spring into the piston

-arrows-.
– Fit outer brake pad to brake carrier.

2. Repairing rear brakes 73

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Bolt brake caliper to brake carrier with both guide pins

-arrows-.
– Fit both cover caps.

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
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ho eo
– Press brake wear sensor
s a cable -4- into bracket on wheel bear‐
ut ra
c
ing housing. s

ce
e
nl

pt
du

– Secure brake wear indicator connectors -3- and -1- in retainer

an
itte

y li
on wheel bearing housing.
erm

ab
ility
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– Secure the brake wear indicator wire in retainer -2- on brake

wit
, is n

caliper.

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Fit retaining spring into upper hole -arrow- and turn anti-clock‐
wise -direction of arrow-.

nform
ercia

– Seat retaining spring into lower section of brake carrier.

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at
om

ion
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in t
or

his
ate

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for

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ng

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by
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– First press retaining spring in -direction of arrow A-, and then
simultaneously into hole in brake caliper
-direction of arrow B-.
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. Gr. 44 ; Specified torques of wheel bolts .

Note

♦ Every time after changing pads, depress brake pedal firmly

several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
♦ Check brake fluid level after changing brake pads.

Specified torque
Brake caliper to brake carrier 30 Nm

74 Rep. Gr.46 - Brakes - mechanism

 AG. Volkswagen AG d
agen
nTouareg 2003 ➤
oes
olksw ot g
V
d by Brake systems - Edition
ua
r 07.2009
e ante
ris
ho eo
ut ra
2.3 Removing and installing brake caliper s a c
s

ce
e
nl

pt
du
Special tools and workshop equipment required

an
itte

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erm

ab
♦ Torque wrench -V.A.G 1331-

ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
m

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

o

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

2.3.1 Removing
This procedure applies only to exchanging or the following repair
work on the brake caliper.
– Remove wheels.
– Press retaining spring in -direction of arrow A- until it can be
pressed out of hole in -direction of arrow B-.

2. Repairing rear brakes 75

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Turn retaining spring -1- clockwise -arrow- until it can be re‐

moved from the upper hole.

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

– Remove brake pad wear indicator wire from brake caliper
housing retainer -2-.
– Remove brake wear indicator lower connector -3- and speed
sensor wire -4- from bracket on brake caliper.
– Connect bleeder bottle hose to brake caliper bleeder valve and
open bleeder valve.
– Apply brake pedal depressor -V.A.G 1869/2- .
– Close bleeder valve and remove bleeder bottle.
– Unscrew brake line.
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gen AG does
swa
– Remove caps -arrows-. yV
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wit
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spec
urposes, in part or in wh

t to the co

– Unscrew and remove both guide pins -arrows- from brake cal‐
rrectne

iper.
– Pull brake caliper off brake carrier.
ss o
cial p

– Remove brake pads from brake caliper.

inform
mer

atio
om

n
c

i
or

n thi
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2.3.2 Installing
py by
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• Piston is pressed back.
• Outer brake pad is seated on brake carrier.
– Insert inner brake pad with retaining spring into brake caliper
(piston).

76 Rep. Gr.46 - Brakes - mechanism

 AG. Volkswagen AG d
agen oes
olksw not
d byV Touareg
gu
ara 2003 ➤
e
oris Brake systems - Edition
nte 07.2009
e
th or
au ac
ss

ce
e
nl

pt
du
Note

an
itte

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erm

ab
The inner brake pad (piston side) is rotation sensitive and is

ility
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therefore marked.

wit
, is n

h re
hole

spec
Directional brake pads

es, in part or in w

t to the co
When installed, the arrow -A- on the brake pad backplate must
point downwards (in direction of brake disc rotation).

rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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cu
– Bolt brake caliper to brake carrier with both guide pins
o

m
f

en
ng

-arrows-.
t.
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Cop py
. rig
– Fit both cover caps.
ht ht
rig by
copy Vo
lksw
– Bolt brake hose to brake caliper.
by
cted agen
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– Remove brake pedal depressor -V.A.G 1869/2- .

– Press brake wear sensor cable -4- into bracket on wheel bear‐
ing housing.
– Secure brake wear indicator connectors -3- and -1- in retainer
on wheel bearing housing.
– Secure the brake wear indicator wire in retainer -2- on brake
caliper.

– Fit retaining spring into upper hole -arrow- and turn anti-clock‐
wise -direction of arrow-.
– Seat retaining spring into lower section of brake carrier.

2. Repairing rear brakes 77

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– First press retaining spring in -direction of arrow A-, and then

simultaneously into hole in brake caliper
-direction of arrow B-.
– Bleed brake system ⇒ page 133 .
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. Gr. 44 ; Specified torques of wheel bolts .

Note

♦ Firmly depress brake pedal several times with vehicle station‐

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

Specified torques:
Guide pin to brake carrier 30 Nm
Brake hose with banjo union and banjo bolt to brake 38 Nm
caliper

2.4 Removing and installing brake shoes

Special tools and workshop equipment required
♦ Hook -3438- n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
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ss

ce
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nl

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an
itte

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ab
ility
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wit
, is n

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spec
es, in part or in w

t to the co

2.4.1 Removing
rrectness of i

– Remove wheels.
l purpos

– Remove brake pads ⇒ page 70 .

– Unbolt brake carrier.
nform
ercia

– Turn brake disc until the parking brake adjustment nut is visible
m

at
om

through a wheel bolt hole.

on
c

in t
or

his
ate

do
priv

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for

en
ng

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t. rig
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pyri by
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by
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Prote AG.

78 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

Resetting parking brake:

– Turn adjustment nut -A- against resistance of spring -B-.
– Remove combined brake disc/brake drum.
– Unhook springs.
– Remove hold-down pins along with springs and remove brake
shoes.

2.4.2 Installing
Install in reverse order.
– Adjusting parking brake ⇒ page 101 .

2.5 Repairing rear brakes, Brembo 17"

brake caliper (1KF)
Period of use: to week 22 of 2006
AG. Volkswagen AG d
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by
Note ised ara
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ut ra
♦ Every time after changings pads, depress brake pedal firmly
s a c
several times with vehicle stationary, so that brake pads are
ce
le
un

pt
properly seated in their normal operating position.
an
d
itte

y li
erm

♦ After work for which the brake system had to be opened, bleed
ab
the brake system with brake filling and bleeding unit - ility
ot p

VAS 5234- or extraction unit -V.A.G 1869/4- . wit

is n

h re
ole,

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

spec
urposes, in part or in wh

brake caliper or disconnecting a brake hose (release pressure

t to the co

in system).
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
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pr

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fo

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

2. Repairing rear brakes 79

 Touareg 2003 ➤
Brake systems - Edition 07.2009

1 - Brake disc/drum
❑ Ventilated brake disc: ∅
330 mm
❑ Brake disc thickness: 28
mm
❑ Wear limit: 26 mm
❑ Brake drum: ∅ 210 mm.
❑ Pad wear limit: 211 mm
❑ Always renew on both
sides of an axle.
❑ For removal, first unbolt
brake caliper. Do not un‐
bolt brake line
2 - Fitted bolt, 14 Nm
❑ Brake disc to wheel hub
3 - Screw plug, 14 Nm
❑ For parking brake ad‐
justment nut. AG. Volkswagen AG d
agen oes
lksw not
4 - Brake caliper d byV
o gu
ara
e nte
❑ Do not disconnect
thoris
brake eo
line when
s au changing ra
c
brake discs.
s
ce
e
nl

pt

❑ Removing and installing

du

an
itte

⇒ page 84
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ab

❑ Repairing ⇒ page 126

ility
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wit
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5 - Multi-point socket head bolt,

h re

180 Nm
hole

spec

❑ Always renew after re‐

es, in part or in w

t to the co

moving
6 - Torx bolt
rrectness of i

7 - Protective plate
l purpos

8 - Brake pads
❑ Thickness: 11 mm not including backplate
nform
ercia

❑ Pad wear limit: 2 mm without backplate

m

at

❑ With break pad wear indicator

om

ion
c

❑ When wear reaches a predetermined limit (approx. 4 mm) the warning lamp in the dash panel insert
in t
or

his
e

comes on.
at

do
riv

❑ Checking thickness: ⇒ Maintenance ; Booklet 17.1 ; Work sequences; Front and rear brake pads/linings:
p

cum
or

Checking thickness .
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❑ Always renew on both sides of an axle. ht. Cop py
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❑ Removing and installing ⇒ page 81 rig ht
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9 - Brake pad wear indicator wire
cted agen
Prote AG.

10 - Securing clip
11 - Pad retaining pin
12 - Retaining spring
13 - Retainer
❑ Bolt to brake caliper housing.

80 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

14 - Hexagon bolt, 8 Nm
15 - Spring clip
16 - Brake line, 14 Nm
❑ Do not disconnect brake line when changing brake discs.
17 - Brake hose
❑ Do not disconnect brake hose when changing brake discs.
❑ Ensure that lugs are properly seated in grooves in bracket.
18 - Hold-down pin
19 - Compression spring
20 - Extension spring
❑ Fitting location: on the adjustment nut.
❑ Identifying the spring ⇒ Item 21 (page 81) :
♦ larger number of spring coils
♦ can be bent easily by hand
21 - Extension spring
❑ Fitting location: on expander
❑ Identifying the spring ⇒ Item 20 (page 81) :
♦ smaller number of spring coils
♦ cannot be bent easily by hand
22 - Expander
23 - Adjustment nut
❑ Adjusting parking brake ⇒ page 101 .. Volkswage
n AG n AG d
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24 - Brake shoe Vol
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❑ Removing and installing
ris
e ⇒ page 86 nte
tho eo
❑ Minimal thicknessa of brake lining: 1 mm
u ra
c
ss
❑ Check thickness.
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e
nl

pt
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an

25 - Brake backplate
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ab

26 - Rear brake cable

ility
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wit
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hole

spec

2.6 Removing and installing brake pads/lin‐

es, in part or in w

t to the co

ings
Special tools and workshop equipment required
rrectness of i

♦ Piston resetting tool -T10145-

l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

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rp

cu
o

m
f

en
ng

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

2. Repairing rear brakes 81

 Touareg 2003 ➤
Brake systems - Edition 07.2009

2.6.1 Removing

Note AG. Volkswagen AG d

agen oes
olksw not
yV gu
Mark brake pads when removing if they ised are to be reused. Fit in
b ara
nte
same position when installing, orutbraking
hor
will be uneven. eo
ra
s a c
s

ce
– Remove wheels.
le
un

pt
an
d
itte

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

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
ercia

– Pull securing clip -arrow- out of pad retaining pin.

m

a
com

tion in
r
te o

thi
s
iva

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rp

cum
fo

en
ng

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

– Press retaining spring inwards -arrow- whilst pulling out pad

retaining pin -1-.

– Pull brake pad wear indicator wire out of brake caliper housing
and out of retaining spring -1-.
– Remove retaining spring.
Before pressing back brake pads, draw off brake fluid from res‐
ervoir. Otherwise, particularly if reservoir has been topped up,
fluid will overflow and cause damage.

82 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Push brake pads off brake disc and remove from brake caliper.
– If the brake pads are to be renewed, carefully remove sensor
with wire for brake pad wear indicator from the brake pads and
check for damage.
Sensors and wires which are not damaged can be used again.
Cleaning:

WARNING

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

– Clean brake caliper.

. Volkswage
Use only methylated spirits for cleaning
ksw
agen the brake caliper
AG n AG d
ohousing.
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2.6.2 Installing ris tee
ho
aut or
ac
ss
Before pressing piston back into cylinder with piston resetting tool,

ce
le

draw off brake fluid from brake fluid reservoir. Otherwise, partic‐
un

pt
an
d

ularly if reservoir has been topped up, fluid will overflow and cause
itte

y li
rm

damage.

ab
pe

ility
ot

– Press pistons back.

wit
, is n

h re
– Carefully insert the sensors of the wire for the brake pad wear
hole

spec
indicator into the new brake pads.
es, in part or in w

t to the co
– Insert brake pads into brake caliper housing.

rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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rp

cum
fo

en
ng

t.
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– Fit retaining spring -1-.
Co
Cop py
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gh
– Insert brake wear indicator wire under the retainer in the re‐
ht
pyri by
taining spring and into brake caliper housing -arrows-.
co Vo
by lksw
cted agen
Prote AG.

2. Repairing rear brakes 83

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Press retaining spring inwards -arrow- and drive in brake pad

retaining pin -1- onto limit stop.

– Secure pad retaining pin with securing clip -arrow-.

AG. Volkswagen AG d
agen oes
olksw not
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d b ara
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ss c

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itte

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ab
pe

ility
ot

wit
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– Reconnect brake wear indicator connector -1- and secure in

h re
hole

retainer on wheel bearing housing.

spec
es, in part or in w

– Fit wheels ⇒ Running gear, axles, steering; Rep. Gr. 44 ;

t to the co
Specified torques of wheel bolts .

rrectness of i
Note
l purpos

♦ Every time after changing pads, depress brake pedal firmly

several times with vehicle stationary, so that brake pads are

nform
ercia

properly seated in their normal operating position.

m

a
com

♦ Check brake fluid level after changing brake pads. tion in

r
te o

thi
s
iva

do

2.7 Removing and installing brake caliper

r
rp

cum
fo

en
ng

Special tools and workshop equipment required

t.
yi Co
Cop py
t. rig
♦ Torque wrench -V.A.G 1332- opyri
gh by
Vo
ht
c by lksw
cted agen
Prote AG.

84 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

♦ Socket, 16 mm -T10198-

AG. Volkswagen AG d
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olksw not
V gu
d by ara
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ce
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an
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♦ Brake pedal depressor -V.A.G 1869/2-

itte

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erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

2.7.1 Removing

atio
om

n
c

This procedure applies only to exchanging or the following repair

i
or

n thi
work on the brake caliper.
te

sd
iva

o
pr

c
– Remove wheels.
um
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fo

en
ng

t.
– Connect bleeder bottle hose to a bleeder valve on brake cali‐
yi Co
op py
per and open bleeder valve. t. C rig
gh ht
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– Apply brake pedal depressor -V.A.G 1869/2- .
op Vo
by c lksw
cted agen
Prote AG.
– Close bleeder valve and remove bleeder bottle.
– Disconnect brake line from brake caliper.
– Remove brake pads ⇒ page 81 .
– Pull speed sensor wire out of retainer on brake caliper.
– Unbolt brake caliper from wheel bearing housing.

2.7.2 Installing
– Bolt brake caliper to wheel bearing housing.
– Install brake pads ⇒ page 81 .
– Reconnect brake line to brake caliper.
– Press speed sensor wire into retainer on brake caliper.
– Remove brake pedal depressor -V.A.G 1869/2- .
– Bleed brake system ⇒ page 133 .
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. Gr. 44 ; Specified torques of wheel bolts .

2. Repairing rear brakes 85

 Touareg 2003 ➤
Brake systems - Edition 07.2009

Note

♦ Firmly depress brake pedal several times with vehicle station‐

ary, so that the brake pads are properly seated in their normal
operating position.
♦ Check brake fluid level.
AG. Volkswagen AG d
agen oes
o lksw not
Specified torques: d by V gu
ara
ise nte
Multi-point socket
thor
head bolt to wheel bearing hous‐ 180 Nmeo
u
ing ss a ra
c
♦ Use new bolts!

ce
le
un

pt
an
d
itte

Brake line to brake caliper 14 Nm

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erm

ab
ility
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2.8 Removing and installing brake shoes

wit
is n

h re
ole,

Special tools and workshop equipment required

spec
urposes, in part or in wh

♦ Hook -3438-

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

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te

sd
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ng

♦ Socket, 16 mm -T10198-
t.
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pyri by
Vo
co lksw
by
cted agen
Prote AG.

2.8.1 Removing
– Remove wheels.
– Remove brake pads ⇒ page 81 .
– Pull speed sensor wire out of retainer on brake caliper.
– Remove securing bolts for brake caliper.
– Remove brake caliper housing and tie up with wire so that
weight of brake caliper does not stretch or damage brake
hose.

86 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Remove screw plug -arrow- for parking brake adjustment nut.

Resetting parking brake:

– Turn adjustment nut -A- against resistance of spring -B-.

– Remove combined brake disc/brake drum.
– Unhook springs.
– Remove hold-down pins along with springs and remove brake
shoes. en AG. V
olkswagen AG
ag does
ksw not
y Vol gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
e
nl

pt
du

an
itte

y li
erm

ab
2.8.2 Installing
ility
ot p

wit
, is n

Install in reverse order.

h re
hole

spec

– Adjusting parking brake ⇒ page 101 .

es, in part or in w

t to the co

2.9 Repairing rear brakes, Brembo 17"

brake caliper (1KQ)
rrectness of i

Period of use: from week 22 of 2006

l purpos

Note
nform
mercia

at

♦ Every time after changing pads, depress brake pedal firmly

om

ion

several times with vehicle stationary, so that brake pads are

c

in t
or

properly seated in their normal operating position.

his
ate

do
riv

♦ After work for which the brake system had to be opened, bleed
p

cum
or

the brake system with brake filling and bleeding unit -

f

en
ng

t.
yi
VAS 5234- or extraction unit -V.A.G 1869/4- .
Co
Cop py
t. rig
♦ Fit brake pedal depressor -V.A.G 1869/2- before removing a
gh ht
pyri by
brake caliper or disconnecting a brake hose (release pressure
co Vo
by lksw
cted
in system).
agen
Prote AG.

2. Repairing rear brakes 87

 Touareg 2003 ➤
Brake systems - Edition 07.2009

1 - Brake disc/drum
❑ Ventilated brake disc: ∅
330 mm
❑ Brake disc thickness: 28
mm
❑ Wear limit: 26 mm
❑ Brake drum: ∅ 210 mm.
❑ Wear limit: 211 mm
❑ Always renew on both
sides of an axle.
❑ For removal, first unbolt
brake caliper. Do not un‐
bolt brake line
2 - Fitted bolt, 14 Nm
❑ Brake disc to wheel hub
3 - Screw plug, 14 Nm
❑ For parking brake ad‐
justment nut.
4 - Brake caliper
❑ Do not disconnect brake
line when changing
brake discs.
❑ Removing and installing
⇒ page 92
❑ Repairing ⇒ page 126
5 - Multi-point socket head bolt,
180 Nm
❑ Always renew after re‐
moving
6 - Brake pads agen
AG. Volkswagen AG d
oes
lksw not
❑ Thickness: 11 mm not d by Vo gu
ara
including backplate orise nte
th eo
❑ Pad wear limit: 2 mm without backplate s au ra
c
s
❑ With break pad wear indicator
ce
le
un

pt
an
❑ When wear reaches a predetermined limit (approx. 4 mm) the warning lamp in the dash panel insert
d
itte

y li

comes on.
rm

ab
pe

ility

❑ Checking thickness: ⇒ Maintenance ; Booklet 17.1 ; Work sequences; Front and rear brake pads/linings:
ot

wit

Checking thickness .
, is n

h re
hole

❑ Always renew on both sides of an axle.

spec
es, in part or in w

❑ Removing and installing ⇒ page 89

t to the co

7 - Brake pad wear indicator wire

8 - Pad retaining pin
rrectness of i

9 - Retaining spring
l purpos

10 - Retainer
nform
ercia

❑ Bolt to brake caliper housing.

m

11 - Hexagon bolt, 8 Nm
a
com

tion in

12 - Spring clip
r
te o

thi
s
iva

13 - Brake line, 14 Nm
do
r
rp

cum

❑ Do not disconnect brake line when changing brake discs.

fo

en
ng

t.
yi Co
14 - Brake hose t. Cop py
rig
gh
❑ Do not disconnect brake hose when changing brake discs.
ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

88 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009
❑ Ensure that lugs are properly seated in grooves in bracket.
15 - Hold-down pin
16 - Compression spring
17 - Extension spring
❑ Fitting location: on the adjustment nut.
❑ Identifying the spring ⇒ Item 18 (page 89) :
♦ larger number of spring coils
♦ can be bent easily by hand
18 - Extension spring
❑ Fitting location: on expander
❑ Identifying the spring ⇒ Item 17 (page 89) :
♦ smaller number of spring coils
♦ cannot be bent easily by ehand
n AG. Volkswagen AG
ag does
ksw not
19 - Expander y Vol gu
b ara
ed nte
ris
20 - Adjustmenttho nut eo
au ra
❑ Adjusting
ss parking brake ⇒ page 101 . c

ce
e
nl

pt
21 - Brake shoe
du

an
itte

❑ Removing and installing ⇒ page 93 y li

erm

ab
❑ Minimal thickness of brake lining: 1 mm ility
ot p

wit
, is n

❑ Check thickness. h re
hole

spec

22 - Brake backplate
es, in part or in w

t to the co

23 - Rear brake cable

rrectness of i

2.10 Removing and installing brake pads/lin‐

l purpos

ings
nform
ercia

Special tools and workshop equipment required

m

♦ Piston resetting tool -T10145-

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

2.10.1 Removing

Note

Mark brake pads when removing if they are to be reused. Fit in

same position when installing, or braking will be uneven.

– Remove wheels.

2. Repairing rear brakes 89

 Touareg 2003 ➤
Brake systems - Edition 07.2009

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

– Drive out brake pad retaining pins -arrows-.

AG. Volkswagen AG d
agen oes
o lksw not
y V gu
d b ara
ise nte
– Pull brake pad thor
wear indicator wire out of brake caliper housing
eo
and out of
ss a retaining spring -1-.
u ra
c
ce
le

– Remove retaining spring.

un

pt
an
d
itte

y li

Before pressing back brake pads, draw off brake fluid from res‐
erm

ab

ervoir. Otherwise, particularly if reservoir has been topped up,

ility
ot p

fluid will overflow and cause damage.

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne

– Push brake pads off brake disc and remove from brake caliper.
ss

– If the brake pads are to be renewed, carefully remove sensor

o
cial p

with wire for brake pad wear indicator from the brake pads and
inform

check for damage.

mer

atio
m

Sensors and wires which are not damaged can be used again.
o

n
c

i
or

Cleaning:
thi
te

sd
iva

o
pr

cum
r
fo

WARNING
en
ng

t.
yi Co
op py
Do not blow out brake system with compressed air; the result‐ t. C rig
gh ht
ing dust constitutes a health hazard! pyri by
Vo
co lksw
by
cted agen
Prote AG.

– Clean brake caliper.

Use only methylated spirits for cleaning the brake caliper housing.

2.10.2 Installing
Before pressing piston back into cylinder with piston resetting tool,
draw off brake fluid from brake fluid reservoir. Otherwise, partic‐

90 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

ularly if reservoir has been topped up, fluid will overflow and cause
damage.
– Press pistons back. AG. Volkswagen AG d
agen oes
lksw not
– Carefully insert the sensors of the wire for the brake
byV
o pad wear gu
ara
indicator into the new brake pads. rised
nte
ho eo
ut
– Insert brake pads into brake caliper housing.
ss a ra
c

ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectne
– Fit retaining spring -1-.

ss o
cial p

f
– Insert brake wear indicator wire under the retainer in the re‐

inform
taining spring and into brake caliper housing -arrows-.
mer

atio
m

– Press retaining spring down and insert brake pad retaining

o

n
c

pins in brake caliper.

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

– Drive brake pad retaining pins into brake caliper to stop.

– Reconnect brake wear indicator connector -1- and secure in

retainer on wheel bearing housing.
– Fit wheels ⇒ Running gear, axles, steering; Rep. Gr. 44 ;
Specified torques of wheel bolts .

Note

♦ Every time after changing pads, depress brake pedal firmly

several times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
♦ Check brake fluid level after changing brake pads.

2. Repairing rear brakes 91

 Touareg 2003 ➤
Brake systems - Edition 07.2009

2.11 Removing and installing brake caliper

Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1332-

n AG. Volkswagen AG do
lkswage es n
o ot g
byV ua
d ran
ir se tee
tho
u or
a ac
♦ Socket, 16 mm -T10198-
ss

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

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

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

2.11.1 Removing
This procedure applies only to exchanging or the following repair
work on the brake caliper.
– Remove wheels.
– Connect bleeder bottle hose to a bleeder valve on brake cali‐
per and open bleeder valve.
– Apply brake pedal depressor -V.A.G 1869/2- .
– Close bleeder valve and remove bleeder bottle.
– Disconnect brake line from brake caliper.
– Remove brake pads ⇒ page 89 .
– Pull speed sensor wire out of retainer on brake caliper.
– Unbolt brake caliper from wheel bearing housing.

92 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
n AG. Volkswagen AG do
lkswage Brake systems - Edition
es n 07.2009
o ot g
byV ua
d ran
2.11.2 Installing tho
ir se tee
or
au ac
– Bolt brake caliper to wheel bearing housing. ss

ce
e
nl

pt
du
– Install brake pads ⇒ page 89 .

an
itte

y li
erm

ab
– Reconnect brake line to brake caliper.

ility
ot p
– Press speed sensor wire into retainer on brake caliper.

wit
, is n

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

spec
es, in part or in w
– Bleed brake system ⇒ page 133 .

t to the co
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;

rrectness of i
Rep. Gr. 44 ; Specified torques of wheel bolts . l purpos

Note

nf
ercia

orm
m

atio
♦ Firmly depress brake pedal several times with vehicle station‐
om

ary, so that the brake pads are properly seated in their normal

n in
or c

operating position.

thi
te

sd
iva

♦ Check brake fluid level.

o
r
rp

cu
o

m
f

en
ng

t.
yi Co
Specified torques: t. Cop py
rig
gh
Multi-point socket head bolt to wheel bearing hous‐ 180 Nm
ht
pyri by
Vo
o
ing
c by lksw
cted agen
♦ Use new bolts! Prote AG.

Brake line to brake caliper 14 Nm

2.12 Removing and installing brake shoes

Special tools and workshop equipment required
♦ Hook -3438-

♦ Socket, 16 mm -T10198-

2. Repairing rear brakes 93

 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
o eo
Touareg 2003 ➤ aut
h
ra
s c
Brake systems - Edition 07.2009 s

ce
e
nl

pt
du

an
2.12.1 Removing

itte

y li
erm

ab
ility
ot p
– Remove wheels.

wit
, is n

h re
– Remove brake pads ⇒ page 89 .

hole

spec
– Pull speed sensor wire out of retainer on brake caliper.

es, in part or in w

t to the co
– Remove securing bolts for brake caliper.
– Remove brake caliper housing and tie up with wire so that

rrectness of i
weight of brake caliper does not stretch or damage brake
hose. l purpos

– Remove screw plug -arrow- for parking brake adjustment nut.

nf
ercia

Resetting parking brake:

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

– Turn adjustment nut -A- against resistance of spring -B-.

– Remove combined brake disc/brake drum.
– Unhook springs.
– Remove hold-down pins along with springs and remove brake
shoes.

2.12.2 Installing
Install in reverse order.
– Adjusting parking brake ⇒ page 101 .

2.13 Repairing rear brakes, 18" brake caliper

Plus
After replacing brake pads/linings, depress brake pedal firmly
several times with vehicle stationary, so that the brake pads/lin‐
ings are properly seated in their normal operating position.
Use brake filling and bleeding equipment -VAS 5234- to draw off
brake fluid from brake fluid reservoir.
Fit brake pedal depressor -V.A.G 1869/2- before removing a
brake caliper or disconnecting a brake hose (release pressure in
system).

94 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

1 - Wheel bearing housing

2 - Splash plate for brake disc
3 - Bolt, 20 Nm
4 - Brake shoes
❑ Without wear indicator
❑ Minimal thickness of
brake lining: 1 mm
❑ Removing and installing
en AG. V
olkswagen AG
⇒ page 100 olkswag does
no
V t gu
by ara
5 - Compression
ris spring
ed nte
ho eo
ut
6 - Hold-down
ss
a pin ra
c

ce
e

7 - Bolt, 20 Nm
nl

pt
du

an
itte

y li
8 - Brake disc/drum
erm

ab
ility
❑ Ventilated brake disc: ∅
ot p

wit
358 mm
, is n

h re
❑ Brake disc thickness: 28
hole

spec
mm
es, in part or in w

t to the co
❑ Wear limit: 26 mm
❑ Brake drum: ∅ 210 mm.
❑ Wear limit: 211 mm

rrectness of i
❑ Always renew on both
l purpos

sides of an axle.
❑ For removal, first unbolt
nform
ercia

brake caliper. Do not un‐

bolt brake line
m

at
om

io

9 - Fitted bolt, 14 Nm
n
c

in t
or

❑ Brake disc to wheel hub

his
ate

do
priv

10 - Screw plug, 14 Nm
um
for

en
g

❑ For parking brake ad‐

n

t.
yi Co
op
justment nut. C py
ht. rig
rig ht
11 - Brake caliper
py by
co Vo
by lksw
cted
❑ Removing and installing ⇒ page 98
agen
Prote AG.

❑ Repairing ⇒ page 126

12 - Brake pad wear indicator wire
13 - Brake hose
❑ Do not disconnect brake hose when changing brake discs.
❑ Ensure that lugs are properly seated in grooves in bracket.
14 - Brake line, 14 Nm
❑ Do not disconnect brake line when changing brake pads or brake disc.
15 - Brake pads
❑ Thickness: 11 mm not including backplate
❑ Wear limit: 2 mm not including backplate
❑ With break pad wear indicator
❑ When wear reaches a predetermined limit (approx. 4 mm) the warning lamp in the dash panel insert
comes on.
❑ Checking thickness: ⇒ Maintenance ; Booklet 17.1 ; Work sequences; Front and rear brake pads/linings:
Checking thickness .
❑ Always renew on both sides of an axle.
❑ Removing and installing ⇒ page 96

2. Repairing rear brakes 95

 Touareg 2003 ➤
Brake systems - Edition 07.2009

16 - Multi-point socket head bolt, 180 Nm

❑ Always renew after removing en AG. Volkswagen AG
ag does
ksw not
17 - Bolt, 8 Nm y Vol gu
b ara
ed nte
ris
18 - Bracket tho eo
au ra
❑ For brake pad swear
s indicator wire c

ce
e
nl

pt
du

an
itte

y li
erm

ab
2.14 Removing and installing brake pads/lin‐

ility
ot p

ings

wit
, is n

h re
hole

Special tools and workshop equipment required

spec
es, in part or in w

♦ Torque wrench -V.A.G 1332-

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

t.
♦ Piston resetting tool -T10145-
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.

2.14.1 Removing

Note

Mark brake pads/linings when removing if they are to be reused.

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

– Remove wheels.

96 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009
AG . Volkswagen AG
– Disconnect connector -1- for brake pad wear indicator.
ksw
agen does
not
Vol
y gu
– Pull brake pad wear indicator wire out of brakeise
d caliper housing
b ara
nte
and out of retaining spring. uthor eo
a ra
s c
– Pull speed sensor wire out of retainers on brake caliper.

ce
le
un

pt
Before pressing back brake pads, draw off brake fluid from res‐

an
d
itte

y li
ervoir. Otherwise, particularly if reservoir has been topped up,

erm

ab
fluid will overflow and cause damage.

ility
ot p

wit
is n
– Push brake pads off brake disc.

h re
– Carefully remove sensor with brake pad wear indicator wire ole,

spec
urposes, in part or in wh
from brake pads and check for damage.

t to the co
Sensors and wires which are not damaged can be used again.
– Unbolt brake caliper from wheel bearing housing.

rrectne
– Remove brake caliper and secure with wire so that weight of
brake caliper does not strain or damage brake hose.

ss o
cial p

f in
– Lever brake pads with a commercially available screwdriver

form
mer

out of brake caliper -arrows-, being careful not to damage dust

atio
m

caps.
o

n
c

i
or

n
– Take brake pads out of retaining springs.

thi
te

sd
iva

o
Cleaning:
pr

cum
r
fo

en
ng

t.
yi Co
op
WARNING C py
t. rig
gh ht
pyri by
Vo
Do not blow out brake system with compressed air; the result‐
co lksw
by
cted agen
ing dust constitutes a health hazard! Prote AG.

– Clean brake caliper.

Use only methylated spirits for cleaning the brake caliper housing.

2.14.2 Installing
Before pressing piston back into cylinder with piston resetting tool,
draw off brake fluid from brake fluid reservoir. Otherwise, partic‐
ularly if reservoir has been topped up, fluid will overflow and cause
damage.
– Press pistons back.
• The retaining spring is correctly seated in the brake caliper.
– Pull protective foil off brake pad backplate.

2. Repairing rear brakes 97

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Insert brake pads into brake caliper and push onto pad retain‐
ing pins -arrows-.

WARNING

The brake pads must be correctly seated in the brake pad re‐
taining springs and on the retaining pins.

– Set brake pads onto contact surfaces of brake pad retaining

springs.
– Carefully set brake caliper over brake disc.
– Bolt brake caliper to wheel bearing housing.
– Press speed sensor wire into retainer on brake caliper.
– Carefully insert sensors of brake pad wear indicator wire into
new brake pads.
– Insert brake pad wear indicator wire under retainers in retain‐
ing spring and into brake caliper housing.

– Reconnect brake wear indicator connector -1- and secure in

retainer on wheel bearing housing.
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. Gr. 44 ; Specified torques of wheel bolts .

Note

♦ Every time after changing pads,

gendepress brake pedal
does firmly
AG. V olksw
agen AG
swa
several times with vehicle y V stationary, so that brake
olk
pads
not
gare
ua
properly seated in rtheirdb
ise normal operating position.
ran
tee
tho or
♦ Check brake fluid
ss au level after changing brake pads. ac
ce
e
nl

pt
du

Specified torques:
an
itte

y li
erm

Multi-point socket head bolt to wheel bearing hous‐ 180 Nm

ab
ility

ing
ot p

wit

♦ Use new bolts!

, is n

h re
hole

spec
es, in part or in w

2.15 Removing and installing brake caliper

t to the co

Special tools and workshop equipment required

rrectness of i

♦ Torque wrench -V.A.G 1332-

l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

98 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

♦ Socket, 16 mm -T10198-

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
♦ Brake orispedal
e depressor -V.A.G 1869/2- nte
eo
th
au ra
ss c

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i

2.15.1 Removing
l purpos

This procedure applies only to exchanging or the following repair

nf
ercia

work on the brake caliper.

orm
m

– Remove wheels.
atio
om

n in
c

– Connect bleeder bottle hose to a bleeder valve on brake cali‐

or

thi
e

per and open bleeder valve.

t

sd
iva

o
r
rp

cu

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

o

m
f

en
ng

t.
yi
– Close bleeder valve and remove bleeder bottle.
Co
Cop py
t. rig
– Separate connector for brake pad wear indicator.
gh ht
pyri by
Vo
co lksw
by
– Disconnect brake line from brake caliper. cted agen
Prote AG.

– Pull speed sensor wire out of retainer on brake caliper.

– Unbolt brake caliper from wheel bearing housing.
– Remove brake pads ⇒ page 96 .

2.15.2 Installing
– Install brake pads ⇒ page 96 .
– Bolt brake caliper to wheel bearing housing.
– Reconnect brake line to brake caliper.
– Press speed sensor wire into retainer on brake caliper.
– Carefully insert sensors of brake pad wear indicator wire into
new brake pads.
– Insert brake pad wear indicator wire under retainers in retain‐
ing spring and into brake caliper housing.
– Reconnect brake wear indicator connector and secure in re‐
tainer on wheel bearing housing.

2. Repairing rear brakes 99

 Touareg 2003 ➤
Brake systems - Edition 07.2009

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

agen oes
ksw
– Bleed brake system ⇒ page 133 . by Vol not
gu
ara
d
ise nte
– Fit wheels. thor eo
au ra
c
Specified torque of wheel bolts ⇒ Running gear, axles, steering; ss

ce
e
Rep. Gr. 44 ; Specified torques of wheel bolts .

nl

pt
du

an
itte

y li
erm

ab
ility
Note

ot p

wit
, is n

h re
♦ Firmly depress brake pedal several times with vehicle station‐ hole

spec
ary, so that the brake pads are properly seated in their normal
es, in part or in w

operating position.

t to the co
♦ Check brake fluid level.

rrectness of i
Specified torques:
l purpos

Multi-point socket head bolt to wheel bearing hous‐ 180 Nm

ing
♦ Use new bolts!

nform
mercia

at
Brake line to brake caliper 14 Nm
om

ion
c

in t
r

2.16 Removing and installing brake shoes

o

his
ate

do
priv

Special tools and workshop equipment required

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for

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ng

t.
♦ Hook -3438-
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♦ Socket, 16 mm -T10198-

2.16.1 Removing
– Remove wheels.
– Pull speed sensor wire out of retainer on brake caliper.
– Remove securing bolts for brake caliper.

100 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
agen
Brake
AG. Volkssystems
wagen AG- Edition 07.2009
does
olksw not
yV gu
– Remove brake caliper housing and tie up with wire riseso
d that
b ara
nte
weight of brake caliper does not stretch or damage
ut
ho brake eo
ra
hose. ss a c

ce
e
nl
– Remove screw plug -arrow- for parking brake adjustment nut.

pt
du

an
itte

y li
Resetting parking brake:

erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

– Turn adjustment nut -A- against resistance of spring -B-.

nform
ercia

– Remove combined brake disc/brake drum.

m

at
om

ion
– Unhook springs.
c

in t
or

his
te

– Remove hold-down pins along with springs and remove brake

a

do
riv

shoes.
p

cum
for

en
ng

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

2.16.2 Installing
Install in reverse order.
– Adjusting parking brake ⇒ page 101 .

2.17 Adjusting parking brake

♦ Adjustment may only be made at both adjustment mecha‐
nisms of the rear axle. The foot operated parking brake lever
and the transfer module on the centre console must not be
adjusted.
♦ Ensure the parking brake cable is routed and guided correctly.
♦ If the brake shoes have been renewed, the free travel must be
set to the 6th tooth. The brake shoes must then be run-in by
a single, smooth braking manoeuvre from approx. 50 km/h
using the foot operated parking brake. The rear wheels must
not block when this is done.
– Parking brake pedal lever in rest position.
– Remove rear wheels.
The brake discs must move freely, press a brake shoe back
slightly or move the rear brake cable to and fro lightly if necessary.

2. Repairing rear brakes 101

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Remove screw plug -arrow- for parking brake adjustment nut.

2.17.1 Adjusting brake shoes on both wheels:

– Insert a screwdriver through the hole in the brake disc and turn
the adjustment nut -A- back against the resistance of the
spring -B- until the brake disc can no longer turn.
– Then loosen the adjustment nut 6 teeth. The brake disc must
then be able to turn freely.
– Then recheck free travel at foot operated parking brake lever.
– Fit wheels.

2.17.2 Checking free travel at foot operated

brake lever: n AG. Volkswagen A ge G do
swa es n
♦ Depress foot operated brake leverby2Voteeth.
lk Wheels must turn ot g
ua
without the brake shoes scraping.
rised ran
tee
tho or
♦ Depress foot operated brake au lever 5 to 7 teeth. Wheels must ac
ss
lock. If the wheels still turn, the parking brake must be adjus‐
ce
e
nl

ted.
pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

102 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

3 Assembly overview - foot-operated

parking brake gen AG
. Volkswagen AG
d wa oes
olks not
byV gu
ara
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ris
3.1 Parking brake pedal au
tho eo
ra
ss c

ce
e
nl

pt
du
1 - Release handle

an
itte

y li
erm

ab
2 - Release cable

ility
ot p

wit
3 - Mounting
, is n

h re
hole

4 - Parking brake pedal

spec
es, in part or in w

❑ Removing and installing

t to the co
⇒ page 105
5 - Hexagon bolt, 23 Nm

rrectness of i
6 - Hexagon bolt, 23 Nm
l purpos

7 - Front brake cable

❑ Removing and installing

nform
ercia

⇒ page 108
m

at
8 - Hexagon bolt, 2 Nm
om

ion
c

in t
r

9 - Contact switch for parking

o

his
te

brake
a

do
priv

cum
for

en
ng

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

3. Assembly overview - foot-operated parking brake 103

 Touareg 2003 ➤
Brake systems - Edition 07.2009

3.2 Transfer module

1 - Transfer module
2 - Washer
3 - Buffer
4 - Cable anchor bracket
5 - Torx bolt
6 - Cable anchor
AG. Volkswagen AG d
7 - Compensator agen oes
olksw not
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ara
8 - Hexagon nut rised
nte
ho eo
ut
9 - Hexagon bolt, 23 sNm
s a ra
c

ce
le

10 - Clip
un

pt
an
d
itte

y li
11 - Front brake cable
erm

ab
❑ Removing and installing

ility
ot p

⇒ page 108

wit
is n

h re
ole,

12 - Rear brake cable

spec
urposes, in part or in wh

❑ Removing and installing

t to the co
⇒ page 107

rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
3.3 Rear brake cable
1 - Rear brake cable
2 - O-ring
3 - O-ring
4 - Sleeve
5 - Retaining ring

104 Rep. Gr.46 - Brakes - mechanism

 agen
AG. Volkswagen AG d
oes Touareg 2003 ➤
ksw
y Vol Brake systems not
-
g uEdition 07.2009
db ara
rise nte
tho eo
3.4 Removing and installing parking brake ss au ra
c
pedal

ce
e
nl

pt
du

an
itte

y li
erm

ab
3.4.1 Removing

ility
ot p

wit
, is n

h re
– Remove driver side trim ⇒ General body repairs, interior; Rep.

hole
Gr. 70 ; Dash panel; Removing and installing dash panel .

spec
es, in part or in w

t to the co
– Pull connector off parking brake contact switch.
– Remove left-hand fuse holder and move fuse holder and wir‐
ing harness as far as possible aside ⇒ Electrical system; Rep.

rrectness of i
Gr. 97 ; Removing and installing fuse holder, relay carrier, E-
boxes and control units; Removing and installing fuse holder .
l purpos

– Remove plastic cover from wheel parking brake pedal.

nf
ercia

o
– First press release spring plate arrow -A- downwards to sub‐

rm
m

sequently press cable adjustment spring together arrow -B-.

atio
om

n in
c

– Continue to press spring arrow -B- together.

or

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

– Lock the compressed spring by inserting a drill (for example)

through the holes in the pedal parking brake -arrow- and the
cable mounting lying behind.

– Unhook brake cable -A- from cable mounting -1- of pedal

parking brake .
– Unhook cable sleeve -2- from mounting.
– Remove both securing bolts for pedal parking brake.
– Remove pedal parking brake from mounting.

3.4.2 Installing
– Install in reverse order.
– Pull transportation device (drill) out of pedal parking brake.

3. Assembly overview - foot-operated parking brake 105

 Touareg 2003 ➤
Brake systems - Edition 07.2009

The spring automatically compensates for the linear difference of

the brake cable.
– Check free travel on parking brake pedal ⇒ page 102 .

AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c

ce
le
un

pt
an
d
itte

y li
rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

106 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

4 Brake cables

4.1 Removing and installing rear brake ca‐

bles

4.1.1 Removing
– Remove both rear wheels.
– Remove centre console ⇒ General body repairs, interior; Rep.
Gr. 68 ; Compartments, covers and trims; Removing and in‐ n AG. Volkswagen AG do
stalling centre console . o lkswage es n
o V t gu
by ara
– Measure dimension -a- before loosening hexagon
ris
ed nut -1-. nte
ho eo
ut
– Note measured value. ss
a ra
c

ce
le

– Turn hexagon nut -1- back until the brake cable can be un‐
un

pt
an
hooked from the compensator.
d
itte

y li
rm

ab
– Unhook cable sleeve from mounting.
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

4.1.2 Unhooking brake cable from expander:

nform
ercia

Only possible when brake cable is not tensioned.

m

– Remove screw plug -arrow- for parking brake adjustment nut.

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

– Press brake cable nipple downwards against retaining spring

in expander until the brake cable can be pulled out.
The right-hand side is a mirror image, which means that the cable
nipple must be pressed upwards.
– Unclip brake cable from retainer on fuel tank.
– Unclip brake cable from retainer on subframe and then pull it
out.

4. Brake cables 107

 Touareg 2003 ➤
Brake systems - Edition 07.2009

4.1.3 Installing
– Install in reverse order.
The brake cable nipple must perceptibly engage in the expander.
– Hook brake cable into compensator.
– Turn hexagon nut -1- on pull rod -2- until the dimension -a-
measured before removal is reinstated.
– Check free travel on parking brake pedal ⇒ page 102 .

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut ra
4.2 Removing and installing front brake ca‐ ss a c

ce
e

ble
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

4.2.1 Removing
wit
, is n

h re
hole

– Remove driver side trim ⇒ General body repairs, interior; Rep.

Gr. 70 ; Dash panel; Removing and installing dash panel . spec
es, in part or in w

t to the co
– Remove centre console ⇒ General body repairs, interior; Rep.
Gr. 68 ; Compartments, covers and trims; Removing and in‐
stalling centre console .
rrectness of i

– Remove entry strip (sill panel) trim ⇒ General body repairs,

l purpos

interior; Rep. Gr. 68 ; Entry strip trim; Removing and installing

entry strip trim .
nform
ercia

– Remove plastic cover from wheel parking brake pedal.

m

at

– First press release spring plate arrow -A- downwards to sub‐

om

ion

sequently press cable adjustment spring together arrow -B-.

c

in t
or

his
te

– Continue to press spring arrow -B- together.

a

do
priv

cum
for

en
ng

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

108 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Lock the compressed spring by inserting a drill (for example)

through the holes in the pedal parking brake -arrow- and the
cable mounting lying behind.

– Unhook brake cable -A- from cable mounting -1- of pedal

parking brake .
– Unhook cable sleeve -2- from mounting.

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

pt
an
d
itte

y li
erm

ab
ility
ot p

– Remove clip -1- and unhook brake cable from cable mounting.
wit
is n

h re
ole,

– Unhook cable sleeve -2- from mounting.

spec
urposes, in part or in wh

– Lift carpet and pull out brake cable.

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

4.2.2 Installing
or

n thi
te

sd
iva

– Install in reverse order.

pr

cum
r
fo

en
ng

– Pull transportation device (drill) out of pedal parking brake.

t.
yi Co
Cop py
The spring automatically compensates for the linear difference of
t. rig
gh ht
yri by
the brake cable. cop Vo
by lksw
cted agen
Prote
– Check free travel on parking brake pedal ⇒ page 102 .
AG.

4. Brake cables 109

 Touareg 2003 ➤
Brake systems - Edition 07.2009

5 Assembly overview - brake pedal (LHD)

Illustration for automatic gearbox

WARNING

The brake pedal travel must not be restricted by additional floor

coverings.

1 - Pedal cluster mounting

bracket
2 - Self-locking hexagon nut, AG. Volkswagen AG d
agen
20 Nm olksw
oes
not
byV gu
ara
d
3 - Pivot pin orise nte
eo
h
ut ra
4 - Brake pedal ss a c

ce
le

5 - Sleeve bearing
un

pt
an
d
itte

y li
6 - Mounting
erm

ab
ility
ot p

❑ For ball head of brake

wit
servo plunger rod.
is n

h re
ole,

7 - Support

spec
urposes, in part or in wh

8 - Hexagon bolt, 8 Nm

t to the co
9 - Crash support

rrectne
10 - Pin
11 - Retaining clip
ss o
12 - Bracket
cial p

f inform

13 - Hexagon bolt, 8 Nm
mer

atio
m

14 - Brake light switch -F- and

o

n
c

brake pedal switch -F47-

or

n thi
te

sd
a

❑ Removing and installing

iv

o
pr

⇒ page 112
cum
r
fo

en
ng

❑ Vehicles from week 48

t.
yi Co
op
of 2006 do not have a C py
ht. rig
brake light switch. rig ht
py by
co Vo
by lksw
cted agen
Prote AG.

5.1 Separating brake pedal from brake ser‐

vo
Special tools and workshop equipment required

110 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

♦ Release tool -T10189-

AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
r
– Remove driver side trim ⇒ General bodyutrepairs, interior; Rep.
ho eo
ra
Gr. 70 ; Dash panel; Removing and installing
ss a
dash panel . c

ce
le

– Remove brake light switch and brake pedal switch

un

pt
an
d

⇒ page 112 .
itte

y li
rm

ab
– Seat release tool -T10189- on push rod mounting in brake
pe

ility
ot

pedal and bracket.

wit
, is n

h re
1 - Brake pedal
hole

spec
es, in part or in w

2 - Plunger rod

t to the co
3 - Retaining lugs
– First press brake pedal slightly towards brake servo and hold

rrectness of i
in position.
l purpos

– Now press release tool -T10189- towards the brake servo,

counterhold on brake pedal when doing this (at this moment

nform
ercia

the pedal must not be allowed to move backwards). This action

will press retaining lugs -3- of mounting off ball head of plunger
m

a
rod -2-.
com

tion in
r

– Continue to press the release tool -T10189- towards the brake

te o

thi
servo whilst simultaneously pulling the brake pedal towards

s
iva

do
r

the driver seat. (This action will pull the brake pedal off the ball
rp

cum
fo

head of the plunger rod).

en
ng

t.
yi Co
Cop py
t. rig
gh ht
yri by
5.1.1 Clipping brake pedal to brake servo
op Vo
by c lksw
cted agen
Prote AG.
– Hold ball head of plunger rod in front of mounting and push
brake pedal in direction of brake servo, so that the ball head
clicks into place.
Continue installation in reverse order.
– Removing and installing brake light switch ⇒ page 112 .

5. Assembly overview - brake pedal (LHD) 111

 Touareg 2003 ➤
Brake systems - Edition 07.2009
AG. Volkswagen AG d
agen oes
lksw not
5.2 Removing and installing brake light Vo gu
d by ara
ise nte
switch -F- and brake pedal switch -F47- or eo
h
aut ra
ss c

ce
e
nl

pt
du
Note

an
itte

y li
erm

ab
ility
Vehicles from week 48 of 2006 do not have a brake light switch.

ot p
The signal is generated by the brake pressure sender -G201- and

wit
, is n

h re
the brake pressure solenoid trip switch -F84- .
hole

spec
es, in part or in w

5.2.1 Brake light switch, old version

t to the co
rrectness of i
Note
l purpos

♦ After removing the old brake light switch (see figure

N46-0359), replace it with a new one (see figure N46-10145).

nform
ercia

♦ Distinguishing features ⇒ page 113 .

m

at
om

ion
c

Removing

in t
or

his
te

– Remove trim on driver's side ⇒ General body repairs, interior;

a

do
riv

Rep. Gr. 70 ; Dash panel

p

cum
for

en
ng

t.
– Pull connector off brake light switch. Cop
yi Co
py
t. rig
The brake light switch may be removed only while operating rod gh ht
yri by
is pressed in (brake pedal is not operated), or the locking mech‐
op Vo
by c lksw
anism of the brake light switch will be damaged.
cted agen
Prote AG.

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

Installing, adjusting and locking
Because old brake light switches may no longer be used, the de‐
scription has been omitted.
Install, adjust and lock new brake light switch.

112 Rep. Gr.46 - Brakes - mechanism

 Touareg 2003 ➤
Brake systems - Edition 07.2009

5.2.2 Brake light switch, new version

Note

♦ Use only new brake light switches.

♦ The most noticeable difference
to the old brake light switch is the new, bright tip of the plunger
-A-.

Removing
– Remove trim on driver's side ⇒ General body repairs, interior;
Rep. Gr. 70 ; Dash panel
– Pull connector off brake light switch.
The brake light switch may be removed only while operating rod
is pressed in (brake pedal is not operated), or the locking mech‐
anism of the brake light switch will be damaged.
G. Volkswage nA n AG d
wage oe
– Remove brakey Vlight
olks switch by turning 45° tosleft.
not
gu b ara
ed
Installing, adjusting
tho
ris and locking nte
e or
au a
Before assembling
ss the brake light switch, grease the bright tip
c of ce

the plunger head with polycarbamide grease G 052 142 A2.

e
nl

pt
du

an
itte

• The brake pedal must remain at rest position while the brake
y li
erm

ab

light switch is being installed. The brake pedal must not be

ility
ot p

touched by anything but the plunger head throughout the en‐

wit
, is n

tire installation.
h re
hole

spec
es, in part or in w

Note
t to the co

The notches in the holes are arranged vertically in the figure; from
vehicle identity number 7L-6-053 601, they are horizontal.
rrectness of i
l purpos

– Guide brake light switch through fitting hole -arrow 1- and

press it against pedal with head of plunger. Then turn brake
nf
ercia

light switch 45° to right -arrow 2- until it can be felt to engage.

rm
m

atio
m

– Fit brake light switch connector.

o

n in
or c

– Check function of brake light.

thi
te

sd
iva

– Install trim on driver's side ⇒ General body repairs, interior;

r
rp

cu
o

Rep. Gr. 70 ; Dash panel

f

en
ng

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

5. Assembly overview - brake pedal (LHD) 113

 Touareg 2003 ➤
Brake systems - Edition 07.2009

47 – Brakes - hydraulics
1 Repairing front brake calipers

1.1 Repairing FN 3 brake calipers

1 - Dust cap
❑ Fit onto bleeder valve.
❑ Secures brake pad wear
indicator wiring.
2 - Bleeder valve, 12 Nm
❑ Before screwing in, ap‐
ply thin coat of assembly
paste -G 052 150 A2- to
thread.
3 - Cover caps
❑ Insert into sleeve bear‐ AG. Volkswagen AG d
agen
ing. Volksw
oes
not
gu
d by ara
4 - Guide pin, 30 Nm orise nte
eo
h
ut ra
5 - Sleeve bearing ss a c

ce
le

❑ Insert into brake caliper.

un

pt
an
d
itte

y li
6 - Brake caliper
rm

ab
pe

7 - Brake carrier ility

ot

wit
, is n

❑ Bolt onto brake caliper. h re

hole

spec
8 - Retaining spring
es, in part or in w

t to the co

❑ Press under brake carri‐

er and insert into both
holes in brake caliper
housing.
rrectness of i

9 - Sealing ring
l purpos

❑ Removing and installing

⇒ page 114
nform
ercia

10 - Piston
m

a
com

tio

❑ Removing and installing

n in
r

⇒ page 114
te o

thi
s
iva

do

11 - Protective cap
r
rp

cum
fo

❑ Take care not to damage when inserting piston.

en
ng

t.
yi Co
Cop py
t. rig
gh ht
pyri by
1.2 Removing and installing piston for brake
o Vo
by c lksw
cted agen
Prote
caliper FN 3
AG.

Special tools and workshop equipment required

114 Rep. Gr.47 - Brakes - hydraulics

 Touareg 2003 ➤
Brake systems - Edition 07.2009

♦ Wedge -3409-

♦ Piston resetting tool -T10145-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c
♦ Assembly tool for protective caps -T10146/1-

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

1.2.1 Removing nform

mercia

– Press piston out of brake caliper using compressed air.

at
om

ion
c

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

in t
or

his
e

piston.
at

do
priv

cum
for

en
ng

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

1. Repairing front brake calipers 115

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Lever off protective cap from brake caliper using wedge

-3409- .
A - Vice clamp

– Remove seal using wedge -3409- .

When removing ensure that the surface of the cylinder is not
damaged.

1.2.2 Installing
– The surfaces of the piston and seal must be cleaned only with
methylated spirits and then dried.
– Apply thin coat of assembly paste -G 052 150 A2- to piston
and sealing ring before inserting.
– Insert seal into brake caliper.
– Fit protective cap -A- in assembly tool -T10146/1-
en AG. V
olkswagen A-1-.
G ag does
ksw not
y Vol gu
b ara
ed nte
oris eo
th
au ra
c
ss
ce
le
un

pt
an
d
itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co

– Press protective cap onto brake caliper so that cap is fitted

correctly all round using assembly tool -T10146/1- -1- and pis‐
ton resetting tool -T10145- -2-.
rrectne

Check seat of protective cap:

ss o
cial p

f inform
mer

atio
om

n
c

i
or

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te

sd
iva

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pr

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r
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en
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t.
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Cop py
t. rig
gh ht
pyri by
Vo
o
116
by c lksw
cted
Rep. Gr.47 - Brakes - hydraulics
agen
Prote AG.
 Touareg 2003 ➤
Brake systems - Edition 07.2009

– At this stage it should not be possible to remove protective cap

from brake caliper by hand.

– Press piston lightly onto protective cap and lock it in this po‐
sition with, for example, an removal wedge -3409- -2-.
Keep piston straight to prevent damage to sealing collar.
– Blow compressed air (max 3 bar) -1- into protective seal. Pro‐
tective cap will spring over the piston.
A - Vice clamp

– Press pistons into brake calipers with piston resetting appli‐

ance -T10145- -1-.
The outer sealing lip on the protective cap will then spring into the
AG. Volkswagen AG d
piston groove. lksw
agen oes
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ility
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is n

h re
ole,

1.3 Repairing Brembo brake calipers (17",

spec
urposes, in part or in wh

18" and 18" Plus)

t to the co

♦ When carrying out repairs, install all parts supplied in repair

kit.
rrectne

♦ Use only methylated spirits for cleaning the brake.

ss

♦ Apply thin coat of assembly paste -G 052 150 A2- to brake

o
cial p

cylinder, piston and seal.

inform
mer

1.3.1 Brake calipers with PR Nos. 1LC and 1LF

atio
om

n
c

i
or

n thi
te

sd
iva

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pr

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

1. Repairing front brake calipers 117

 Touareg 2003 ➤
Brake systems - Edition 07.2009

1 - Dust cap
❑ Fit onto bleeder valve.
❑ Secures brake pad wear
indicator wiring.
2 - Bleeder valve, 12 Nm
❑ Before screwing in, ap‐
ply thin coat of assembly
paste -G 052 150 A2- to
thread.
❑ 10 mm
3 - Brake caliper
4 - Seal for 34/30 mm piston
❑ Removing and installing
⇒ page 120
5 - Seal for 36/34 mm piston
❑ Removing and installing
⇒ page 120
6 - Seal for 38 mm piston
❑ Removing and installing
⇒ page 120
7 - Piston, 34/30 mm
❑ Removing and installing
⇒ page 120 agen
AG. Volkswagen AG d
oes
lksw not
❑ Apply thin coat of as‐ byV
o gu
ara
sembly paste -G 052 rised
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150 A2- to piston before aut
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inserting. ss c

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nl

8 - Piston, 36/34 mm

pt
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❑ Removing and installing
erm

ab
⇒ page 120

ility
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wit
❑ Apply thin coat of as‐
, is n

h re
sembly paste -G 052
hole

150 A2- to piston before inserting.

spec
es, in part or in w

t to the co
9 - Piston, 38 mm
❑ Removing and installing ⇒ page 120
❑ Apply thin coat of assembly paste -G 052 150 A2- to piston before inserting. rrectness of i
10 - Protective seal for 34/30 mm piston
l purpos

❑ Take care not to damage when inserting piston.

nf
ercia

11 - Protective seal for 36/34 mm piston

orm

❑ Take care not to damage when inserting piston.

m

atio
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n in

12 - Protective caps for 38 mm piston

or c

thi
e

❑ Take care not to damage when inserting piston.

t

sd
iva

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rp

cu

13 - Connecting pipe, 17 Nm
o

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

118 Rep. Gr.47 - Brakes - hydraulics

 Touareg 2003 ➤
Brake systems - Edition 07.2009

1.3.2 Brake caliper with PR No. 1LE

1 - Dust cap
❑ Fit onto bleeder valve.
❑ Secures brake pad wear
indicator wiring.
2 - Bleeder valve, 12 Nm
❑ Before screwing in, ap‐
ply thin coat of assembly n AG. Volkswagen AG do
paste -G 052 150 A2- to lkswage es n
o ot g
thread. byV ua
d ran
ir se tee
❑ 8 mm utho
or
a ac
ss
3 - Brake caliper

ce
e
nl

pt
du
4 - Sealing ring

an
itte

y li
erm

❑ Removing and installing

ab
ility
⇒ page 120
ot p

wit
, is n

5 - Piston, 46 mm

h re
hole

spec
❑ Removing and installing
es, in part or in w

⇒ page 120

t to the co
❑ Apply thin coat of as‐
sembly paste -G 052
150 A2- to piston before

rrectness of i
inserting.
l purpos

6 - Protective cap
❑ Take care not to dam‐

nform
ercia

age when inserting pis‐

ton.
m

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

1. Repairing front brake calipers 119

 Touareg 2003 ➤
Brake systems - Edition 07.2009

1.3.3 Brake calipers with PR Nos. 1LT and 1LU

1 - Bleeder valve, 12 Nm
❑ Before screwing in, ap‐
ply thin coat of assembly
paste -G 052 150 A2- to
thread.
❑ 11 mm
2 - Dust cap
❑ Fit onto bleeder valve.
3 - Brake caliper
4 - Retaining spring
5 - Piston seal
❑ Removing and installing
⇒ page 120
6 - Piston, 36 mm
❑ Removing and installing
⇒ page 120
❑ Apply thin coat of as‐
sembly paste -G 052
150 A2- to piston before
inserting.
7 - Protective caps for piston
❑ Take care not to dam‐
age when inserting pis‐
ton. n AG. Volkswagen AG do
lkswage es n
o ot g
8 - Retainer d byV ua
ran
ir se
❑ For brake pad wear in‐ tho tee
or
dicator wire ss
au ac
ce
le

9 - Connecting pipe, 17 Nm
un

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ab
ility
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ole,

spec
urposes, in part or in wh

1.4 Removing and installing Brembo brake

t to the co

caliper piston (17", 18" and 18" Plus)

Removal and installation of pistons is identical though brake cal‐
rrectne

ipers are different.

Special tools and workshop equipment required
ss o
cial p

♦ Wedge -3409-
inform
mer

atio
om

n
c

i
or

n thi
te

sd
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pr

cum
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en
ng

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

120 Rep. Gr.47 - Brakes - hydraulics

 Touareg 2003 ➤
Brake systems - Edition 07.2009

♦ Piston resetting tool -T10145-

1.4.1 Removing
– Press pistons individually out of brake caliper using com‐
pressed air.
Only one piston can be pressed out at a time. Hold opposing pis‐
ton in brake caliper using piston resetting tool -a-. Block the other
pistons with, for example, a wooden block -b-. Additionally, place
a piece of wood -c- in front of piston resetting tool so that piston
is not damaged when being pressed out.

– Remove seal using wedge -3409- G. . Volkswage

nA n AG d
wage oe
When removing ensure that Vothe
lks surface of the cylinder sisnonot
t gu
by
damaged. ise
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nl

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itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

1.4.2 Installing
– The surfaces of the piston and seal must be cleaned only with
rrectness of i

methylated spirits and then dried.

l purpos

– Apply thin coat of assembly paste -G 052 150 A2- to piston

and sealing ring before inserting.
nf
ercia

– Insert seal in brake caliper.

rm
m

atio
om

n in
or c

thi
te

sd
iva

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rp

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

1. Repairing front brake calipers 121

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Place protective cap on piston.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
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aut ra
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pt
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ab
– Using equal pressure, push piston into brake caliper.
pe

ility
ot

wit
The protective cap should locate securely in the groove. If not,
, is n

h re
use piston resetting tool to push piston in slightly.
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
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rp

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

122 Rep. Gr.47 - Brakes - hydraulics

 Touareg 2003 ➤
Brake systems - Edition 07.2009

2 Repairing rear brake calipers

2.1 Repairing FN 44 brake calipers

1 - Dust cap
❑ Fit onto bleeder valve.
❑ Secures brake pad wear
indicator wiring.
AG. Volkswagen AG d
agen oes
2 - Bleeder valve, 12 Nm Volksw not
gu
by ara
❑ Before screwing in, ap‐ rised
nte
ply thin coat of assembly aut
ho eo
ra
paste -G 052 150 A2- to ss c
thread.

ce
e
nl

pt
du

an
itte

3 - Cover caps

y li
erm

ab
❑ Insert into sleeve bear‐

ility
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ing.

wit
, is n

h re
4 - Guide pin, 30 Nm
hole

spec
es, in part or in w

5 - Sleeve bearing

t to the co
❑ Insert into brake caliper.
6 - Brake caliper

rrectness of i
7 - Brake carrier
l purpos

❑ Bolt onto brake caliper.

8 - Retaining spring

nform
ercia

❑ Press under brake carri‐

m

at
er and insert into both
om

ion
holes in brake caliper
c

in t
or

housing.

his
ate

do
riv

9 - Sealing ring
p

cum
for

en
g

❑ Removing and installing

n

t.
yi Co
⇒ page 123 t. Cop py
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10 - Piston p by
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❑ Removing and installing
cted agen
Prote AG.
⇒ page 123
11 - Protective cap
❑ Take care not to damage when inserting piston.

2.2 Removing and installing piston for FN 44

brake caliper
Special tools and workshop equipment required

2. Repairing rear brake calipers 123

 Touareg 2003 ➤
Brake systems - Edition 07.2009

♦ Wedge -3409-

♦ Piston resetting tool -T10145-

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
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un

pt
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d

♦ Assembly tool for protective caps -T10146/1-

itte

y li
erm

ab
ility
ot p

wit
is n

h re
ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

2.2.1 Removing
atio
om

n
c

– Press piston out of brake caliper using compressed air.

i
or

n thi
te

sd
a

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

iv

o
pr

piston.
um
r
fo

en
ng

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

124 Rep. Gr.47 - Brakes - hydraulics

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Lever off protective cap from brake caliper using removal

wedge -3409- .
A - Vice clamp

– Remove seal using removal wedge -3409- .

When removing ensure that the surface of the cylinder is not
damaged.

2.2.2 Installing
– The surfaces of the piston and seal must be cleaned only with
methylated spirits and then dried.
– Apply thin coat of assembly paste -G 052 150 A2- to piston
and sealing ring before inserting.
– Insert seal into brake caliper. n AG. Volkswagen AG do
lkswage es n
o ot g
– Fit protective cap -A- in assembly d by Vtool -T10146/4- -1-. ua
ran
ir se tee
tho
u or
a ac
ss
ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co

– Press protective cap onto brake caliper so that cap is fitted

rrectness of i

correctly all round using assembly tool -T10146/4- -1- and pis‐
l purpos

ton resetting tool -T10145- -2-.

Check seat of protective cap:
nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

2. Repairing rear brake calipers 125

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– At this stage it should not be possible to remove protective cap

from brake caliper by hand.

– Press piston lightly onto protective cap and lock it in this po‐
sition with, for example, an removal wedge -3409- -2-.
Keep piston straight to prevent damage to sealing collar.
– Blow compressed air (max 3 bar) -1- into protective seal. Pro‐
tective cap will spring over the piston.
A - Vice clamp

– Press pistons into brake calipers with piston resetting appli‐

ance -T10145- -1-.
. Volkswagen AG
gen AG d
The outer sealing lip on theVol
kprotective
swa cap will then spring
oes
not into the
piston groove. ed by gu
ara
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ce
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nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

2.3 Repairing Brembo brake calipers

t to the co

(17"and 18" Plus)

rrectness of i

♦ When carrying out repairs, install all parts supplied in repair

kit.
l purpos

♦ Use only methylated spirits for cleaning the brake.

nform
ercia

♦ Apply thin coat of assembly paste -G 052 150 A2- to brake

cylinder, piston and seal.
m

at
om

io

2.3.1 17" brake calipers with PR No. 1KF

n
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

126 Rep. Gr.47 - Brakes - hydraulics

 Touareg 2003 ➤
Brake systems - Edition 07.2009

1 - Dust cap
❑ Fit onto bleeder valve.
2 - Bleeder valve, 12 Nm
❑ Before screwing in, ap‐
ply thin coat of assembly
paste -G 052 150 A2- to
thread.
❑ 10 mm
3 - Brake caliper
4 - Seal for 28 mm piston
❑ Removing and installing
⇒ page 129
5 - Seal for 30 mm piston
❑ Removing and installing
⇒ page 129
6 - Piston, 28 mm AG. Volkswagen AG d
agen oes
ksw
❑ Removing and installing byV
ol not
gu
ara
⇒ page 129 rised
nte
ho eo
❑ Apply thin coat of as‐ aut ra
c
sembly paste -G 052 ss

ce
e

150 A2- to piston before

nl

pt
du

an
inserting.
itte

y li
erm

ab
7 - Piston, 30 mm

ility
ot p

❑ Removing and installing

wit
, is n

h re
⇒ page 129
hole

spec
❑ First coat piston lightly
es, in part or in w

with.

t to the co
8 - Protective caps for 28 mm
piston

rrectness of i
❑ Take care not to dam‐
age when inserting pis‐
l purpos

ton.
9 - Protective caps for 30 mm piston

nform
ercia

❑ Take care not to damage when inserting piston.

m

at
om

io
10 - Connecting pipe, 17 Nm

n
c

in t
or

his
e

11 - Torx bolt
at

do
priv

cum

12 - Protective plate
for

en
ng

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

2. Repairing rear brake calipers 127

 Touareg 2003 ➤
Brake systems - Edition 07.2009

2.3.2 17" brake calipers with PR No. 1KQ

1 - Dust cap
❑ Fit onto bleeder valve.
2 - Bleeder valve, 12 Nm
❑ Before screwing in, ap‐
ply thin coat of assembly
paste -G 052 150 A2- to
thread.
❑ 8 mm
3 - Brake caliper
4 - Sealing ring
❑ Removing and installing
⇒ page 129
5 - Piston, 44 mm
❑ Removing and installing
⇒ page 129
❑ Apply thin coat of as‐
sembly paste -G 052
150 A2- to piston before
inserting.
6 - Protective cap
❑ Take care not to dam‐
age when inserting pis‐
ton.

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

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

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or c

thi
te

sd
iva

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rp

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en
ng

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

128 Rep. Gr.47 - Brakes - hydraulics

 Touareg 2003 ➤
Brake systems - Edition 07.2009

2.3.3 18" Plus brake caliper

1 - Bleeder valve, 12 Nm
❑ Before screwing in, ap‐
ply thin coat of assembly
paste -G 052 150 A2- to
thread.
❑ 11 mm
2 - Dust cap
❑ Fit onto bleeder valve.
3 - Brake caliper
4 - Retaining spring
5 - Piston seal
❑ Removing and installing
⇒ page 129
6 - Piston, 30 mm
❑ Removing and installing
⇒ page 129
❑ Apply thin coat of as‐
sembly paste -G 052
150 A2- to piston before AG. Volkswagen AG d
inserting. agen oes
olksw not
V gu
by ara
7 - Protective caps for piston rised
nte
ho eo
❑ Take care not to dam‐ aut ra
c
age when inserting pis‐ ss

ce
e

ton.
nl

pt
du

an
itte

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erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

2.4 Removing and installing rear brake cal‐

iper piston
nf
ercia

or

Removal and installation of pistons is identical though brake cal‐

m
m

atio

ipers are different.

om

n in
or c

Special tools and workshop equipment required

thi
te

sd
iva

♦ Wedge -3409-
o
r
rp

cu
o

m
f

en
ng

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

2. Repairing rear brake calipers 129

 Touareg 2003 ➤
Brake systems - Edition 07.2009

♦ Piston resetting tool -T10145-

2.4.1 Removing
– Press pistons individually out of brake caliper housing using
compressed air.
Only one piston can be pressed out at a time. When doing this,
hold the opposing piston in the caliper using the piston resetting
appliance -a-. Block the other pistons with, for example, a wooden
block -b-. Additionally, place a piece of wood -c- in front of piston
resetting tool so that piston is not damaged when being pressed
out.

– Remove seal using wedge -3409- .

When removing ensure that the surface of the cylinder is not
damaged.

AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara
ed
ris nte
ho eo
aut ra
ss c ce
e
nl

pt
du

an
itte

y li
erm

2.4.2 Installing
ab
ility
ot p

wit

– The surfaces of the piston and seal must be cleaned only with
, is n

h re

methylated spirits and then dried.

hole

spec

– Apply thin coat of assembly paste -G 052 150 A2- to piston

es, in part or in w

t to the co

and sealing ring before inserting.

– Insert oil seal in brake caliper housing.
rrectness of i
l purpos

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

t.
yi Co
Cop py
ht. rig
rig ht
py by

130
co Vo
by lksw
cted
Rep. Gr.47 - Brakes - hydraulics
agen
Prote AG.
 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Place protective cap on piston.

AG. Volkswagen
– Using equal pressure, push piston
lksw
into
agenbrake caliper A
housing.
G do
es n
o ot g
yV ua
The protective cap should locate
rise
d b securely in the groove. If not, ran
tee
use piston resetting tool tothopush piston in slightly. or
s au ac
s

ce
e
nl

pt
du

an
itte

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
te

sd
iva

o
r
rp

cu
o

m
f

en
ng

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

2. Repairing rear brake calipers 131

 Touareg 2003 ➤
AG. Volkswagen AG d
Brake systems - Edition 07.2009 ksw
agen oes
not
ol
byV gu
ara
ed
ris nte
3 Pressurised leak test ho eo
aut ra
ss c

ce
e
Special tools and workshop equipment required

nl

pt
du

an
itte
♦ Tester for brake pressure regulator -V.A.G 1310 A-

y li
erm

ab
ility
ot p

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
Test prerequisites:
m

atio
om

n in
c

Brake system (hydraulic unit, brake hoses, brake lines and brake
or

thi
calipers) operating properly and free of leaks.
te

sd
iva

o
r

– Remove bleeder valve at one of front brake calipers.

rp

cu
o

m
f

en
ng

t.
– Connect tester for brake pressure regulator -V.A.G 1310 A- op
yi Co
and bleed.
C py
ht. rig
rig ht
py by
– Apply pressure to brake pedal until gauge indicates a pressure co Vo
by lksw
of 50 bar. The pressure must not drop by more than 4 bar
cted agen
Prote AG.
within the test period of 45 seconds. Renew brake master cyl‐
inder if drop in pressure exceeds specification.

132 Rep. Gr.47 - Brakes - hydraulics

 Touareg 2003 ➤
Brake systems - Edition 07.2009

4 Bleeding brake system

Bleeding the brake system is described for brake filling and bleed‐
ing equipment -VAS 5234- and -V.A.G 1869- .

Note

♦ Bleeding brake system on vehicles with ABS is performed in

same way as vehicles with a conventional brake system.
♦ Only use new brake fluid conforming to USn A
standard
G. Volkswagen A
FMVSS 116 DOT 4. ksw
age G do
es n
y Vol ot g
ua
b
♦ Genuine VW/Audi brake fluidrisconforms
ed to this specification. ran
tee
tho
or
♦ Brake fluid is poisonous.ssAlso due to its corrosive effect brake
au ac
fluid must not come into contact with paintwork.

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le
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♦ Brake fluid is hygroscopic, which means it absorbs moisture

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from the ambient air and should therefore always be stored in
erm

ab
air tight containers.

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is n

♦ Rinse off spilled brake fluid using plenty of water.

h re
ole,

spec
urposes, in part or in wh

A pre-pressure of 2 bar is required for bleeding the hydraulic unit.

t to the co
4.1 Bleeding brake system with brake filling
and bleeding unit -VAS 5234- or brake

rrectne
filling and bleeding unit -V.A.G 1869-

ss
Special tools and workshop equipment required

o
cial p

f in
♦ Brake filling and bleeding equipment -VAS 5234- or

form
mer

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om

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c

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or

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Prote AG.

♦ Brake filling and bleeding equipment -V.A.G 1869-

♦ Upgrade kit and extraction unit -V.A.G 1869/4-

4. Bleeding brake system 133

 Touareg 2003 ➤
Brake systems - Edition 07.2009

Note

If a chamber in brake fluid reservoir is completely empty (e.g.

brake system leaking), brake system must be pre-bled first.

4.1.1 Pre-bleeding:
♦ Brembo brake calipers have two bleed valves. Always bleed
brake calipers at both bleed valves.
♦ Bleed outer bleed valve first.
– Connect brake filling and bleeding unit -VAS 5234- or -
V.A.G 1869- .
Bleeding sequence:
1 - Bleed front left and front right brake calipers simultaneously.
2 - Bleed rear left and rear right brake calipers simultaneously.
– Leave bleed valves open until, with bleed hoses still fitted,
brake fluid discharges free of air bubbles.
Then the hydraulic unit must be bled again with tester -VAS 5051-
via function “basic settings” (default settings).
Initiate basic setting (to bleed brake system):
Connecting -VAS 5051- and selecting functions ⇒ page 11 .
– Then bleed brake system as normal.
Basic (default) settings for brake pressure sender -G201- must
be performed after bleeding brake system.

4.1.2 Bleeding (normal):

Adhere strictly to work sequence when bleeding brake system.
♦ Brembo brake calipers have two bleed valves. Always bleed
brake calipers at both bleed
swa
gen AGvalves.
. Volkswagen AG
does
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♦ Bleed outer bleed
ed
by valve first. ara
nte
is
or e
– Connectaubrake
th filling and bleeding unit -VAS 5234- or - or a
V.A.G 1869-
ss . c
ce
e
nl

pt

– Open bleed valves in the specified order and bleed brake cal‐
du

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ipers.
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ility

1 - Rear right brake caliper

ot p

wit
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2 - Rear left brake caliper

h re
hole

spec

3 - Front right brake caliper

es, in part or in w

t to the co

4 - Front left brake caliper

Use suitable bleed hose. It must sit tightly on bleeder valve so that
rrectness of i

no air can enter brake system.

l purpos

– Leave brake caliper bleed valves open until, with bleed hoses
still fitted, brake fluid discharges free of air bubbles.
nf
ercia

4.1.3 Subsequent bleeding

orm
m

atio
m

To do this a second mechanic is required:

o

n in
or c

– Depress brake pedal forcefully and hold.

thi
te

sd
iva

– Open bleed valve on brake caliper.

r
rp

cu
o

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f

en
ng

– Press brake pedal down onto limit stop.

t.
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Cop py
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rig ht
py by

134
co Vo
by lksw
cted
Rep. Gr.47 - Brakes - hydraulics
agen
Prote AG.
 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Close bleed valve with pedal held down.

– Release brake pedal slowly.
This bleed sequence must be carried out 5 times per brake cali‐
per.
Bleeding sequence:
1 - Rear right brake caliper
2 - Rear left brake caliper
3 - Front right brake caliper . Volkswagen AG
gen AG does
swa
4 - Front left brake caliper y Volk not
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e db ara
nte
A road test must be carried out after
horis
brakes have been bled. When eo
ut
doing this, an ABS regulations amust occur at least once! ra
s c

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le

4.2 Changing brake fluid

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4.2.1 Changing brake fluid
ot

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hole

⇒ Maintenance ; Booklet 17.1

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

4. Bleeding brake system 135

 AG. Volkswagen AG d
agen oes
olksw not
Touareg 2003 ➤ d byV gu
ara
e
Brake systems - Edition 07.2009 horis nte
eo
aut ra
ss c

ce
le
5 Assembly overview - brake servo/brake master cylinder

un

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erm

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ility
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Note

wit
is n

h re
ole,
Use only new brake fluid. Observe information on brake fluid reservoir!

spec
urposes, in part or in wh

t to the co
1 - Pedal cluster mounting
bracket

rrectne
2 - Self-locking hexagon nut,
25 Nm

ss o
cial p

❑ Renew each time after

f in
removing.

form
mer

atio
3 - Brake pedal
om

n
c

i
or

n
4 - Gasket

thi
te

sd
a

❑ For brake servo.

iv

o
pr

cum
r
fo

5 - Tandem brake servo

en
ng

t.
yi Co
❑ Including brake pres‐ . Cop py
sure solenoid trip switch
ht rig
rig ht
by
-F84- and brake pres‐ copy Vo
by lksw
sure solenoid valve - cted agen
Prote AG.
N247- (cannot be re‐
newed)
❑ On petrol engines, the
required vacuum is tak‐
en from the intake mani‐
fold.
❑ Vehicles with a petrol
engine and an automat‐
ic gearbox are equipped
with a brake vacuum
pump.
❑ Diesel engines are fitted
with a vacuum pump to
create the required vac‐
uum.
❑ Functional check:
– With engine switched
off, depress brake pedal
firmly several times (to
exhaust vacuum in unit).

– Now step on and hold brake pedal with medium pressure and start engine. If the brake servo is functioning
properly, the brake pedal will be felt to go down as the servo takes effect.
❑ If faulty renew complete (check all vacuum lines first).
❑ Removing and installing ⇒ page 144
6 - Sealing ring
7 - Potentiometer for brake servo diaphragm travel -G420-
❑ Removing and installing ⇒ page 137
❑ Discontinued from week 48/06
8 - Snap ring
9 - Sealing ring
10 - Self-locking hexagon nut, 25 Nm
❑ Renew each time after removing.

136 Rep. Gr.47 - Brakes - hydraulics

 Touareg 2003 ➤
Brake systems - Edition 07.2009

11 - Brake line, 14 Nm
❑ Brake master cylinder/primary piston circuit to hydraulic unit.
❑ Marked on hydraulic unit with -DK-.
12 - Brake line, 14 Nm
❑ Master brake cylinder/secondary piston circuit to hydraulic unit.
❑ Marked on hydraulic unit with -SK-.
13 - Brake pressure sender -G201-
❑ Removing and installing ⇒ page 138 .
❑ From week 48/06 in ESP unit
14 - Bracket
15 - Brake line
❑ To front left brake caliper.
16 - Brake master cylinder
❑ Cannot be repaired. If faulty, renew as a complete unit.
❑ Removing and installing ⇒ page 142
17 - Sealing plug
❑ Moisten with brake fluid and press into brake fluid reservoir.
18 - Brake fluid reservoir
19 - Cap
AG. Volkswagen AG d
20 - Vacuum hose ksw
agen oes
not
Vol
❑ Insert into brake servo unit. ed by gu
ara
ris nte
o
21 - Sealing plug aut
h eo
ra
s c
❑ Connection for vacuum hose s

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ab
5.1 Removing and installing diaphragm
pe

ility
ot

wit
movement potentiometer in brake servo
, is n

h re
hole

-G420-
spec
es, in part or in w

t to the co

5.1.1 Removing
rrectness of i

– Remove plenum chamber cover ⇒ General body repairs, ex‐

l purpos

terior; Rep. Gr. 64 ; Flush bonded windows; Removing and

installing plenum chamber cover .
nform
ercia

– Take E-box (on left in plenum chamber) out of retainer and

place as far as possible aside ⇒ Electrical system; Rep. Gr.
m

97 ; Removing and installing fuse holder, relay carrier, E-box‐

com

tio

es and control units; Removing and installing E-box on left in

n in
r
te o

plenum chamber .
thi
s
iva

do

– Pull connector off potentiometer for brake servo diaphragm

r
rp

cum
fo

travel.
en
ng

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

5. Assembly overview - brake servo/brake master cylinder 137

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Lever snap ring out of groove -arrow- and pull potentiometer

for brake servo diaphragm travel out of brake servo.

5.1.2 Installing
Install in reverse order.

5.2 Removing and installing brake pressure

sender -G201-
The brake pressure regulator is located on the brake main cylin‐
der to week 48/06.

5.2.1 Removing
– Remove brake master cylinder ⇒ page 142 .
– Remove brake pressure sender -G201- .

5.2.2 Installing
– Install in reverse order.
Torque settings
Brake pressure sender -G201- 33 Nm
AG. Volkswagen AG d
agen
– Bleed brake system ⇒ page 133 . Volksw
oes
not
by gu
d ara
Basic (default) settings for brake pressure sender -G201-ormust
ise nte
eo
be performed after bleeding brake system. aut
h
ra
ss c
Connecting -VAS 5051- and selecting functions ⇒ page 11 .
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le
un

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itte

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erm

ab
ility
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wit
is n

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ole,

spec
urposes, in part or in wh

t to the co
rrectness o
cial p

f inform
mer

atio
om

n
c

i
or

n thi
te

sd
iva

o
pr

cum
r
fo

en
ng

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

138 Rep. Gr.47 - Brakes - hydraulics

 Touareg 2003 ➤
Brake systems - Edition 07.2009

6 Brake servo vacuum supply

6.1 Overview - vacuum pump for brake ser‐

vo (diesel vehicles)
Vacuum pump for 5-cyl. diesel engine:
Must not be dismantled.
Tandem pump -4- (vacuum pump and fuel pump)
Vacuum hose to brake servo -1- with non-return valve.
Fuel lines -2 and 3-.
– Removing and installing tandem pump ⇒ 5-cyl. diesel engine;
Rep. Gr. 20 ; Removing and installing parts of fuel supply
system .
Vacuum pump for 6-cyl. diesel engine: AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
ut
Must not be dismantled. ss a ra
c

ce
e

Vacuum pump -2-

nl

pt
du

an
itte

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Vacuum hose to brake servo -3- with non-return valve.
erm

ab
ility
ot p

– Removing and installing the vacuum pump ⇒ 6-cylinder diesel

wit
, is n

engine (3.0 l engine, common rail); Rep. Gr. 15 ; Cylinder

h re
head; Assembly overview - vacuum pump .
hole

spec
Vacuum pump for 10-cyl. diesel engine:
es, in part or in w

t to the co
rrectness of i
l purpos

nf
ercia

orm
m

atio
om

n in
or c

thi
e

Must not be dismantled.

t

sd
iva

o
r
rp

cu

Tandem pump -5- (vacuum pump and fuel pump)

o

m
f

en
ng

t.
yi
Vacuum hose to brake servo -1- with non-return valve.
Co
Cop py
t. rig
gh
Fuel lines -2 and 4-.
ht
pyri by
Vo
o
by c lksw
– Removing and installing tandem pump ⇒ 10-cyl. diesel en‐
cted agen
Prote AG.
gine; Rep. Gr. 20 ; Removing and installing parts of fuel supply
system .

6.2 Assembly overview - vacuum pump for brakes -V192-

Applies only to vehicles with a petrol engine and an automatic
gearbox.

6. Brake servo vacuum supply 139

 Touareg 2003 ➤
Brake systems - Edition 07.2009

1 - Brake servo pressure sen‐

sor -G294-
2 - Vacuum hose
❑ To brake servo.
3 - Brake servo relay -J569-
❑ Removing and installing
⇒ Current flow dia‐
grams .
4 - Non-return valve
Functional check
⇒ page 141 .

5 - Clamp-type clip
❑ Renew.
6 - Clip
7 - Bump stop
8 - Vacuum pump for brakes -
V192-
❑ Removing and installing
⇒ page 140
9 - Bump stop
10 - Bracket
❑ Allocation ⇒ Electronic
Parts Catalogue (ETKA)
11 - Nut
AG. Volkswagen AG d
agen oes
12 - Hexagon bolt Volksw not
gu
d by ara
ise nte
or eo
h
aut ra
ss c

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e
nl

pt
du

an
itte

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erm

ab
ility
ot p

6.2.1 Removing and installing brake vacuum

wit
, is n

pump -V192-
h re
hole

spec
No provision is made for repairs to brake vacuum pump -V192- .
es, in part or in w

t to the co
If a fault occurs, the brake vacuum pump -V192- must be re‐
newed.
Removing
rrectness of i

– Separate connection -1-.

l purpos

– Pull vacuum hose -2- off brake vacuum pump -V192- .

nform
mercia

at
om

ion
c

in t
or

his
ate

do
priv

cum
for

en
ng

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

140 Rep. Gr.47 - Brakes - hydraulics

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Release clip in direction of arrow and remove. AG. Volkswagen AG d

agen oes
ksw
– Pull brake vacuum pump -V192- upwards outbof y V bracket.
o l not
gu
ara
d
ise nte
Installing thor eo
au ra
c
Install in reverse order. ss

ce
le
un

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d
itte

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rm

ab
pe

ility
ot

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
6.3 Checking non-return valve
Air must pass through valve in direction of arrow.

rrectness of i
Valve must remain closed in opposite direction.
l purpos

Observe correct installation position.

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

6. Brake servo vacuum supply 141

 Touareg 2003 ➤
Brake systems - Edition 07.2009

7 Removing and installing brake mas‐

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

7.1 Removing
– Remove plenum chamber cover ⇒ General body repairs, ex‐
terior; Rep. Gr. 64 ; Flush bonded windows; Removing and
installing plenum chamber cover .
– Remove engine compartment seal and
agen
AG.cover
Volkswstrip
agen Ain
G dvicinity
oes
of brake servo. Volksw not
g y ua
db ran
– Remove front panel h(bulkhead)
or
ise of plenum chamber. tee
t or
au ac
– Place sufficient lint-free
ss cloths in plenum chamber in the area
of the brake master cylinder.
ce
le
un

pt
an
d
itte

– Draw off as much brake fluid as possible from brake fluid res‐
y li
rm

ab

ervoir using brake filling and bleeding unit -VAS 5234- or

pe

ility

extraction unit upgrade set -V.A.G 1869/4- .

ot

wit
, is n

h re

– Pull connector off brake fluid level warning contact -F34- .

hole

spec

– Pull connector off brake pressure sender.

es, in part or in w

t to the co

– On vehicles with a manual gearbox, pull off clutch master cyl‐

inder supply hose and seal with a plug.
rrectness of i

– Remove brake fluid reservoir. To do this press locking tabs on

the reservoir outwards and simultaneously pull the brake fluid
l purpos

reservoir out of the sealing plugs.

– Pull the front left brake line out of retainer on brake master
nform
ercia

cylinder.
m

– Disconnect brake lines from brake master cylinder and seal

com

tion in

brake lines with sealing plugs -1H0 698 311 A- from repair kit.
r
te o

thi
s

– Unscrew brake master cylinder nuts.

iva

do
r
rp

cum

– Carefully take brake master cylinder out of brake servo unit.

fo

en
ng

t.
yi Co
7.2 Installing Cop py
t. rig
gh ht
pyri by
– Install in reverse order.
co Vo
by lksw
cted agen
Prote AG.
Observe the following points when installing:
– When fitting together the brake master cylinder and brake ser‐
vo unit, ensure that the push rod is correctly located in the
brake master cylinder.
Sealing ring between brake master cylinder and brake servo is
fitted.

142 Rep. Gr.47 - Brakes - hydraulics

 AG. Volkswagen AG d
agen oes
olksw not
byV gu
ara Touareg 2003 ➤
ed
ris nt
ut
ho Brake systemsee- oEdition
ra
07.2009
a c
ss
– Bleed brake system ⇒ page 133 .

ce
le
un

pt
an
d
itte
Basic (default) settings for brake pressure sender -G201- must

y li
rm

ab
be performed after bleeding brake system.

pe

ility
ot
Connecting -VAS 5051- and selecting functions ⇒ page 11 .

wit
, is n

h re
hole

spec
es, in part or in w

t to the co
rrectness of i
l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

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

7. Removing and installing brake master cylinder 143

 Touareg 2003 ➤
Brake systems - Edition 07.2009

8 Removing and installing brake servo

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

AG. Volkswagen AG d
agen
8.1 Removing
oes
olksw not
V gu
d by ara
ise nte
– Remove driver side trim ⇒ General body repairs,hor interior; Rep. eo
Gr. 70 ; Dash panel; Removing and installingaut dash panel . ra
ss c

ce
e

– Remove brake light switch/brake pedal switch ⇒ page 112 .

nl

pt
du

an
itte

y li
– Remove bracket for brake light switch.
erm

ab
ility
ot p

– Separate brake pedal from brake servo ⇒ page 110 .

wit
, is n

h re
– Remove support on bearing bracket, through which push rod
hole

to brake servo runs.

spec
es, in part or in w

– Remove plenum chamber cover ⇒ General body repairs, ex‐

t to the co
terior; Rep. Gr. 64 ; Flush bonded windows; Removing and
installing plenum chamber cover .

rrectness of i
– Remove engine compartment seal and cover strip in vicinity
of brake servo.
l purpos

– Remove front panel (bulkhead) of plenum chamber.

nform
ercia

– Pull connector off brake pressure sender.

m

at
– Pull connector off brake fluid level warning contact -F34- .
om

ion
c

in t
r

– Disconnect earth cable from earth point on body behind E-box,

o

his
te

take wiring harness (running behind brake servo) out of re‐

a

do
riv

tainer and place aside.

p

cum
for

en
ng

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

144 Rep. Gr.47 - Brakes - hydraulics

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Take E-box (on left in plenum chamber) out of retainer and

place as far as possible aside ⇒ Electrical system; Rep. Gr.
97 ; Removing and installing fuse holder, relay carrier, E-box‐
es and control units; Removing and installing E-box on left in
plenum chamber .
– Place sufficient lint-free cloths in plenum chamber in the area
of the brake master cylinder.
– Draw off as much brake fluid as possible from brake fluid res‐
ervoir using brake filling and bleeding equipment -VAS 5234-
or extraction unit -V.A.G 1869/4- .
– On vehicles with a manual gearbox, pull off clutch master cyl‐
inder supply hose and seal with a plug.
– Remove brake fluid reservoir. To do this press locking tabs on
the reservoir outwards and simultaneously pull the brake fluid
reservoir out of the sealing plugs.
– Pull the front left brake line out of retainer on brake master
cylinder. AG. Volkswagen n AG do
ks wage es
– Disconnect brake lines from Vol brake master cylinder and oseal
n t
gu
by
brake lines with sealing
ris
e plugs -1H0 698 311 A- .
d ara
nt ee
tho or
– Unscrew brakes amaster
u cylinder nuts. ac
s

ce
le

– Carefully take brake master cylinder out of brake servo unit.

un

pt
an
d
itte

– Remove diaphragm movement potentiometer ⇒ page 137 .

y li
rm

ab
pe

ility
– Pull vacuum hose out of brake servo.
ot

wit
, is n

– Take brake lines out of triple retainer on brake servo.

h re
hole

– Disconnect front left brake line at connecting point in front left spec
es, in part or in w

wheel housing. t to the co

– Unscrew nuts from brake servo unit.

rrectness of i

– Carefully remove brake servo from plenum chamber.

l purpos

nform
mercia

a
com

tion in
r
te o

thi
s
iva

do
r
rp

cum
fo

en
ng

t.
yi Co
Cop py
t. rig
gh
8.2 Installing
ht
pyri by
Vo
co lksw
by
cted agen
Prote
– Install in reverse order.
AG.

Observe following points when installing:

Joining brake pedal to brake servo
– Hold ball head of plunger rod in front of mounting and push
brake pedal in direction of brake servo, so that the ball head
clicks into place.
– After installing, bleed brakes ⇒ page 133 and clutch.
Basic (default) settings for brake pressure sender -G201- must
be performed after bleeding brake system.
Connecting -VAS 5051- and selecting functions ⇒ page 11 .
– Removing and installing brake light switch ⇒ page 112 .

8. Removing and installing brake servo 145

 Touareg 2003 ➤
Brake systems - Edition 07.2009

9 Repairing brake lines

The flanging tool for brake lines -VAS 6056- can be used to flange
brake lines with an outer pipe diameter of 5 mm without damaging
the coating. In certain cases, this enables partial brake line sec‐
tions to be renewed at less expense.
Working with flaring 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 reveal deformations which constrict the line cross-sec‐
tion to an impermissible degree.
♦ Preferably separate brake lines at vehicle floor.
♦ The position of the adapters must be selected so that these
cannot chafe on moving parts.
♦ Do not grease spindle; merely clean with spirit.

Special tools and workshop equipment required

♦ Flanging tool for brake lines -VAS 6056-

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

ce
e
nl

♦ Brake filling and bleeding unit -VAS 5234-

pt
du

an
itte

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List of individual tools:
erm

ab
ility
ot p

Item Tool Tool number

wit
, is n

h re
1 Flanging tool (including flanging VAS 6056/1
hole

jaws VAS 6056/6) spec

es, in part or in w

t to the co
2 Pipe cutter VAS 6056/2
3 Brake line scraper1) VAS 6056/3
rrectness of i

4 Set of grips with plastic jaws VAS 6056/4

5 Pipe bending tool VAS 6056/5
l purpos

6 Special wrench, 6 mm -
nform
ercia

7 Flanging jaws VAS 6056/7

m

at

1) Grub screws (in shaft and at side) are adjusted and must not be readjusted!
om

ion
c

in t
or

9.1 Assembly overview - flanging tool

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146 Rep. Gr.47 - Brakes - hydraulics

 Touareg 2003 ➤
Brake systems - Edition 07.2009

1 - Flanging tool upper part

❑ Unbolt to change flang‐
ing jaws.
2 - Fastening for handle
❑ Must be removed to ac‐
cess retaining screw for
upper part
3 - Retaining screw
❑ For flanging tool upper
part.
4 - Grub screws for flanging
jaws
❑ Centring and holding
the flanging jaws.
❑ Allen head bolt, 2 mm. AG. Volkswagen AG d
agen oes
ksw
5 - Flanging jaws by
Vol not
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❑ Various. horis nte
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❑ Assembly instructions ss a ra
c
⇒ page 147 .

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Flanging jaw assembly instructions:
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♦ VAS 6056/6 (dark) for black brake lines

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♦ VAS 6056/7 (light) for green brake lines

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Arrow on rounded side of flanging jaws must point to edge of
AG.

housing, and straight side of flanging jaws must be installed to

spindle, as flanging head is not otherwise formed correctly.

9.2 Work instructions

– Unbolt relevant brake line at brake caliper or wheel brake cyl‐
inder; catch escaping brake fluid and dispose of this as per
regulations.

9. Repairing brake lines 147

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Cut through brake line at a suitable point (straight, freely ac‐

cessible section) with pipe cutter -2-.
– Remove section to be renewed.
– Degrease brake line surface.

– Clamp brake line tightly in set of grips -4- so that approx. 50

mm project from plastic jaws.
– Clamp scraper -3- into a drill and position onto brake line.
– At slow drill speed and applying gentle pressure on brake line,
scrape off brake line coating. agen
AG. Volkswagen AG d
oe w s no
olks t gu
Length of scraping is determined by
ed
bstop
y V in scraper. ara
is nte
or
– Withdraw scraper from brake
au
th line and remove scraping resi‐ eo
ra
dues. ss c

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– Remove set of grips and slide pipe bolt -D- onto brake line.

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hole

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es, in part or in w

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rrectness of i
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tion in

– Slide brake line -B- up to stop -A- in flanging tool.

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Brake line must be positioned up to stop when tightening the Allen t. C rig
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head bolts, as the flanging head is otherwise not formed correctly. pyri by
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– Tighten brake line in flanging tool until brake line can no longer
be moved. Fold up stop -A- and now tighten Allen head bolts
diagonally using special wrench -C-.

148 Rep. Gr.47 - Brakes - hydraulics

 Touareg 2003 ➤
Brake systems - Edition 07.2009

– Turn spindle to stop in flanging tool.

– Turn spindle back again.
– Loosen Allen head bolts diagonally.
AG. Volkswagen AG d
agen oes
– Remove brake line from flanging tool, clean lksw check brake
oand not
yV gu
line and flanging head. ise
d b ara
nte
r
ho eo
Briefly flush the section of brake lines aremaining
ut in the vehicle: ra
c
s
– Connect brake filling and bleeding unit -VAS 5234- , connect

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le
un

pt
bleeder bottle hose to brake line flange and allow brake filling

an
d
itte

y li
and bleeding unit -VAS 5234- to run briefly until a little brake
erm

ab
fluid has run through.

ility
ot p

wit
is n

– Blow out the new brake line to be inserted with compressed

h re
air.
ole,

spec
urposes, in part or in wh

t to the co
– Join brake lines with the connector -E-.
– Install brake line.

rrectne
– Bleed brake system ⇒ page 133 .

ss o
cial p

f inform
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atio
om

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Prote AG.

9. Repairing brake lines 149