Volkswagen Touareg 2010 Workshop Manual
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Volkswagen Touareg 2010 Workshop Manual

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Service
Workshop Manual
Touareg 2010 ➤
Brake systems
Edition 05.2011
Service Department. Technical Information

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Summary of Contents for Volkswagen Touareg 2010

  • Page 1 Service Workshop Manual Touareg 2010 ➤ Brake systems Edition 05.2011 Service Department. Technical Information...
  • Page 2 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 © 2011 Volkswagen AG, Wolfsburg D3E80297240...

  • Page 3: Table Of Contents

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Contents 00 - Technical data ........... .
  • Page 4 Touareg 2010 ➤ Brake systems - Edition 05.2011 Removing and installing brake pedal ......... .

  • Page 5: Technical Data

    Touareg 2010 ➤ Brake systems - Edition 05.2011 00 – Technical data Brake allocation via PR No. The type of brake system installed in the vehicle is indicated among other things by the corresponding PR number on the ve‐ hicle data sticker.
  • Page 6 Touareg 2010 ➤ Brake systems - Edition 05.2011 3.0l - 245 kW TSI, hy‐ brid Rep. gr.00 - Technical data...

  • Page 7: Technical Data

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Technical data Brake master cylinder and brake servo Brake master cylinder ∅ in mm 26,99 Brake servo ∅ in inches 9" / 10" - tandem Front brakes 2.2.1 Front brake, Brembo (17") Item PR No.

  • Page 8: Rear Brakes

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Rear brakes 2.3.1 Rear brakes (17" brake disc) Item PR No. 1KJ / 1KQ Brake caliper Brembo (17") Brake lining, thickness Brake pad, wear limit without backplate Brake disc ∅ in mm...

  • Page 9: Brake Test

    The brake test must be performed on a single-axle roller dyna‐ mometer. The maximum test speed must not exceed 6 km/h. The test rigs authorised by Volkswagen fulfil these requirements. Testing vehicles with electric differential lock The brake test must be performed on a regulated contra-rotating roller brake test stand.
  • Page 10 Touareg 2010 ➤ Brake systems - Edition 05.2011 Entering »TÜV mode« is indicated by the yellow electric parking brake and handbrake fault warning lamp -K214- lighting up. End »TÜV mode«: • Release electromechanical parking brake using electrome‐ chanical parking brake button -E538- .

  • Page 11: Anti-Lock Brake System

    Touareg 2010 ➤ Brake systems - Edition 05.2011 45 – Anti-lock brake system 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 front and rear.

  • Page 12: Notes For Repair Work On The Abs

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Notes for repair work on the ABS ♦ Before carrying out repair work on the anti-lock brake system, determine the cause of the fault using „Guided Fault Finding“. „Guided fault finding“ is carried out on the vehicle diagnosis, test‐...

  • Page 13: Connecting Vas 5051 And Selecting Functions

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Connecting -VAS 5051- and select‐ ing functions Special tools and workshop equipment required ♦ -VAS 5051- Vehicle Diagnosis, Testing and Information Sys‐ ♦ Diagnosis cable -VAS 5051/1- or -VAS 5051/3- WARNING ♦ During a road test, you must always secure testing and measuring equipment on the back seat.
  • Page 14 Touareg 2010 ➤ Brake systems - Edition 05.2011 – 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 on screen. Guided Fault Finding –...

  • Page 15: Electrical/Electronic Components And Locations

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Electrical/electronic components and locations 1 - ABS control unit -J104- ❑ Location: on hydraulic unit on right suspension strut. ❑ Do not separate con‐ nector before success‐ fully completing self-di‐ agnosis. Switch ignition off before separating connector.
  • Page 16 Touareg 2010 ➤ Brake systems - Edition 05.2011 ❑ Combined lateral acceleration sender -G200- , yaw rate sender -G202- and longitudinal acceleration sender -G251- . ❑ Combined in one housing. ❑ Observe installation instructions ⇒ page 26 12 - Diagnostic connection ❑...

  • Page 17: Assembly Overview - Hydraulic Unit

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Assembly overview - hydraulic unit ABS MK 25 1 - ABS control unit -J104- ❑ Removing and installing ⇒ page 18 2 - ABS hydraulic unit -N55- ❑ Removing and installing ⇒ page 18 3 - Torx bolt, 2+0.8 Nm...
  • Page 18 Touareg 2010 ➤ Brake systems - Edition 05.2011 13 - Brake line, 14 Nm ❑ To rear right brake caliper. ❑ Identification: ∅ 5.25 mm and union nut with thread M10 x 1 Connecting brake lines from brake master cylinder to hydraulic...
  • Page 19 Touareg 2010 ➤ Brake systems - Edition 05.2011 Removing: – Note or request radio code on vehicles with coded radio if necessary. – Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐ necting and reconnecting battery . – Remove air intake pipe (not fitted on all engines), release hose clips -arrows- and pull off hose -1-.
  • Page 20 Touareg 2010 ➤ Brake systems - Edition 05.2011 Continuation for all vehicles – Remove bolts -arrows- on coolant expansion tank -1-. – Slide coolant expansion tank -1- in -direction of arrow- out of retainer. – Place coolant expansion tank -1- to one side.
  • Page 21 Touareg 2010 ➤ Brake systems - Edition 05.2011 The illustration shows the expansion tank -1- removed and placed on side. – Check valve for damage. – Clean sealing surface. Note Do not use aggressive cleaning agents (use enclosed clean‐ ♦...
  • Page 22 Touareg 2010 ➤ Brake systems - Edition 05.2011 5.1.2 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- Sealing plugs repair kit, Part No.
  • Page 23 Touareg 2010 ➤ Brake systems - Edition 05.2011 WARNING Do not bend the brake lines in the area of the hydraulic unit! 5.1.3 Removing control unit and hydraulic unit – Note or request radio code on vehicles with coded radio if necessary.
  • Page 24 Touareg 2010 ➤ Brake systems - Edition 05.2011 – Connect bleed hose of bleed bottle -1- to bleed valve of rear left brake caliper. – Open bleed valve. – Depress brake pedal at least 60mm using brake pedal de‐ pressor -V.A.G 1869/2- .
  • Page 25 Touareg 2010 ➤ Brake systems - Edition 05.2011 – Without canting it, pull control unit off from hydraulic unit -arrow-. WARNING ♦ Printed circuit board becomes visible when control unit is removed. ♦ No moisture or particles of dirt may enter control unit.
  • Page 26 Touareg 2010 ➤ Brake systems - Edition 05.2011 WARNING Ensure that rubber dampers are not pressed out of bracket when installing. After installing, check hydraulic unit with con‐ trol unit for proper seating, otherwise malfunctions can occur. – Remove brake pedal depressor -V.A.G 1869/2- .

  • Page 27: Removing And Installing Parts Of Abs System On Front And Rear Axle

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Removing and installing parts of ABS system on front and rear axle 1 - ABS speed sensor ❑ Before inserting sensor, clean fitting hole inner surface and coat with polycarbamide grease - G 052 142 A2- .

  • Page 28: Removing And Installing Parts Of Abs System On Rear Axle

    Touareg 2010 ➤ Brake systems - Edition 05.2011 – 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. 6.1.2 Installing –...

  • Page 29: Removing And Installing Speed Sensor On Rear Axle

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Removing and installing speed sensor on rear axle 6.3.1 Removing – Raise vehicle. – Remove wheel. – Remove brake caliper and secure with wire so that weight of brake caliper does not strain or damage brake hose.

  • Page 30: Removing And Installing Parts Of Esp System

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Removing and installing parts of ESP system Removing and installing ESP sensor unit -G419- The lateral acceleration sender -G200- , the yaw rate sender - G202- and the longitudinal acceleration sender -G251- are in‐...

  • Page 31: Removing And Installing Steering Angle Sender G85

    Touareg 2010 ➤ Brake systems - Edition 05.2011 7.1.2 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. Do not use the securing nuts to forcibly position ESP sensor unit.

  • Page 32: Brakes - Mechanism

    Touareg 2010 ➤ Brake systems - Edition 05.2011 46 – Brakes - mechanism Repairing front brakes Assembly overview - front brake, Brem‐ bo 17" 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.

  • Page 33: Removing And Installing Brake Pads/Linings

    Touareg 2010 ➤ Brake systems - Edition 05.2011 5 - Retaining spring 6 - Pad retaining pins 7 - Hexagon bolt, 270 Nm ❑ Always renew after removing. 8 - Brake pad wear indicator wire. 9 - Brake linings ❑ Thickness: 11 mm not including backplate.
  • Page 34 Touareg 2010 ➤ Brake systems - Edition 05.2011 – Disconnect connector -1- for brake pad wear indicator. – Pull off dust cap -2- and lift off brake pad wear indicator wire. – Drive out brake pad retaining pins -arrows-. – Pull brake pad wear indicator wire -arrows- out of brake caliper and out of retaining spring -1-.
  • Page 35 Touareg 2010 ➤ Brake systems - Edition 05.2011 ularly if reservoir has been topped up, fluid will overflow and cause damage. – Press pistons back. – Carefully insert sensors of brake pad wear indicator wire into new brake pads. – Insert brake pads into brake caliper.

  • Page 36: Removing And Installing Brake Caliper

    Touareg 2010 ➤ Brake systems - Edition 05.2011 – 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.
  • Page 37 Touareg 2010 ➤ Brake systems - Edition 05.2011 1.3.1 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‐...

  • Page 38: Assembly Overview - Front Brake, Brembo 18

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Assembly overview - front brake, Brem‐ bo 18" 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.

  • Page 39: Removing And Installing Brake Pads/Linings

    Touareg 2010 ➤ Brake systems - Edition 05.2011 8 - Brake linings ❑ Thickness: 10 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.
  • Page 40 Touareg 2010 ➤ Brake systems - Edition 05.2011 ♦ Piston resetting appliance -T10145- 1.5.1 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.
  • Page 41 Touareg 2010 ➤ Brake systems - Edition 05.2011 – Remove multi-point socket head bolts -A- from brake caliper. – Fit assembly pins -T10439- for this. – Then push brake caliper forwards -movement arrow- until cal‐ iper engages in recesses -arrows- of assembly pins -T10439- .
  • Page 42 Touareg 2010 ➤ Brake systems - Edition 05.2011 1.5.2 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.

  • Page 43: Removing And Installing Brake Caliper

    Touareg 2010 ➤ Brake systems - Edition 05.2011 – Insert brake pad wear indicator connector -arrow- into retainer. – Reconnect connector -1- to speed sensor. – Fit wheels. Specified torque of wheel bolts ⇒ Running gear, axles, steering; Rep. gr. 44 ; Specified torques of wheel bolts .
  • Page 44 Touareg 2010 ➤ Brake systems - Edition 05.2011 ♦ Brake pedal depressor -V.A.G 1869/2- 1.6.1 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‐...
  • Page 45 Touareg 2010 ➤ Brake systems - Edition 05.2011 Specified torques: Multi-point socket head bolt to wheel bearing hous‐ 30 Nm + 90° ♦ Use new bolts! Brake hose to brake caliper 14 Nm 1. Repairing front brakes...

  • Page 46: Repairing Rear Brakes

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Repairing rear brakes Assembly overview - rear brake caliper, 17" After replacing brake pads/linings, depress brake pedal firmly several times with vehicle stationary so that the brake pads/linings are properly seated in their normal operating position.
  • Page 47 Touareg 2010 ➤ Brake systems - Edition 05.2011 7 - Brake pad wear indicator wire. 8 - Brake caliper ❑ Removing and installing ⇒ page 46 ❑ Repairing ⇒ page 71 9 - Multi-point socket head bolt, 30 Nm + 75°...

  • Page 48: Removing And Installing Brake Pads/Linings

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Removing and installing brake pads/lin‐ ings Special tools and workshop equipment required ♦ Torque wrench -V.A.G 1332- ♦ Piston resetting appliance -T10145- 2.2.1 Removing Note Mark brake pads/linings when removing if they are to be reused.
  • Page 49 Touareg 2010 ➤ Brake systems - Edition 05.2011 – Lever brake pads out of brake caliper -arrows- using a com‐ mercially available screwdriver, not to damage dust caps when doing this. – Also take brake pads out of brake caliper.

  • Page 50: Removing And Installing Brake Caliper

    Touareg 2010 ➤ Brake systems - Edition 05.2011 – Insert brake wear indicator connector -2- into retainer on brake caliper. – Fit wheels. Specified torque of wheel bolts ⇒ Running gear, axles, steering; Rep. gr. 44 ; Specified torques of wheel bolts .

  • Page 51: Removing And Installing Brake Shoes

    Touareg 2010 ➤ Brake systems - Edition 05.2011 – Close bleeder valve and remove bleeder bottle. – Disconnect connector for brake pad wear indicator. – Pull brake pad wear indicator wire out of brake caliper. – Disconnect brake line from brake caliper.
  • Page 52 Touareg 2010 ➤ Brake systems - Edition 05.2011 2.4.1 Removing Note Mark brake pads/shoes when removing if they are to be reused. Fit in same position when installing, otherwise different air gap and braking will be uneven. – Remove rear wheels.

  • Page 53: Adjusting Air Gap

    Touareg 2010 ➤ Brake systems - Edition 05.2011 – Detach tension spring -1- and return spring -2-. – Remove hold-down pins -3 + 4- along with compression springs and remove brake shoes. 2.4.2 Installing Install in reverse order. Additional work:...
  • Page 54 Touareg 2010 ➤ Brake systems - Edition 05.2011 Evaluation Specification / Actual value 2 or Difference left/right air 0 - 0.2 mm / 0.93 mm gaps: Specification (black lettering) Actual value within tolerance (blue lettering) Actual value outside tolerance (red lettering) If air gap lies outside tolerance, carry out following procedures: –...
  • Page 55 Touareg 2010 ➤ Brake systems - Edition 05.2011 Right adjustment nut: ♦ Turning in arrow direction -A- reduces air gap (= tightens). ♦ Turning in arrow direction -B- increases air gap (= loosens). ♦ Arrow -C- shows the direction of travel (forwards).

  • Page 56: Repairing Thread In Brake Caliper Connection

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Repairing thread in brake caliper con‐ nection For vehicles with aluminium wheel bearing housing Note All operations while repairing the thread must be carried out man‐ ually without additional tools. List of individual tools for VAS 6627: 1 - Drilling jig 2 - Fitted bolt M12x1.5...
  • Page 57 Touareg 2010 ➤ Brake systems - Edition 05.2011 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.
  • Page 58 Touareg 2010 ➤ Brake systems - Edition 05.2011 – Manually drill until gripping tool -1- touches brass sleeve -3- -arrow A-. – Loosen fitted bolt -2- slightly and then swing drilling jig -1- to one side. – Clamp seat milling cutter -2- in gripping tool -1- and counter‐...
  • Page 59 Touareg 2010 ➤ Brake systems - Edition 05.2011 – To check depth of countersink, place insert -1- other way round, i.e. with seat -A- first, into countersink. Seat of insert must disappear fully inside countersink. – Remove swarf, wear safety goggles.
  • Page 60 Touareg 2010 ➤ Brake systems - Edition 05.2011 – Manually cut thread until gripping tool -1- touches brass sleeve -3- -arrow A-. – Clean bore, remove swarf and cutting oil, wear safety goggles. – Turn insert -1- manually onto driving tool -2- until you can feel slight resistance.

  • Page 61: Overview Of Electromechanical Parking Brake Components

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Overview of electromechanical parking brake components 1 - Electromechanical parking brake button -E538- ❑ Location: in centre con‐ sole. 2 - Electromechanical parking brake warning lamp -K213- ❑ Location: in electrome‐ chanical parking brake button -E538- .

  • Page 62: Removing And Installing Control Unit For Electromechanical Parking Brake J540

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Removing and installing control unit for electromechanical parking brake -J540- The electromechanical parking brake control unit -J540- is loca‐ ted behind the right luggage compartment side panel trim. After control unit for electromechanical parking brake -J540- has been replaced, recode ABS control unit -J104- and carry out basic setting of „brake system“...
  • Page 63 Touareg 2010 ➤ Brake systems - Edition 05.2011 ♦ Diagnosis cable -VAS 5051/1- or -VAS 5051/3- Removing Note Do not separate connectors of parking brake motors. • Electromechanical parking brake not operated. Connecting -VAS 5051- and selecting functions ⇒ page 9 –...
  • Page 64 Touareg 2010 ➤ Brake systems - Edition 05.2011 – Secure parking brake motor mounting with cable tie -2- to pre‐ vent it turning. – Unscrew brake carrier plate. – Release and disconnect connector -1- on parking brake motor. – Remove parking brake motor electrical wiring from clip and remove clip.

  • Page 65: Assembly Overview - Brake Pedal

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Assembly overview - brake pedal Illustration for automatic gearbox and hybrid model WARNING The brake pedal travel must not be restricted by additional floor coverings. ♦ Lubricate all bearing and contact surfaces with grease -G 000 450 02- .

  • Page 66: Separating Brake Pedal From Brake Servo

    Touareg 2010 ➤ Brake systems - Edition 05.2011 15 - Brake pedal position sender -G100- retainer ❑ Only with hybrid models. ❑ Adjusting ⇒ page 64 16 - Bolt, 3 Nm ❑ Only with hybrid models. 17 - Retaining ring ❑...

  • Page 67: Removing And Installing Brake Pedal

    Touareg 2010 ➤ Brake systems - Edition 05.2011 5.1.1 Clipping 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.

  • Page 68: Adjusting Brake Pedal Position Sender G100

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Continuation for both vehicles – Unscrew bolts -arrows- and remove crash wedge -1- from mounting bracket -2-. – Separate brake pedal -3- from brake servo ⇒ page 62 – Pull split pin -arrow- off pivot pin -1-.
  • Page 69 Touareg 2010 ➤ Brake systems - Edition 05.2011 – Remove convenience system central control unit -J393- with retainer ⇒ Electrical system; Rep. gr. 97 ; Control units . Brake pedal position sender -G100- retainer, guide ribs -A- and bearing bracket -B- have slots to provide a sideways adjustment.
  • Page 70 Touareg 2010 ➤ Brake systems - Edition 05.2011 Both engaged fasteners -3- are shown on figure. – Tighten bolt -4- of magnet retainer. – Push stop tab -1- in -direction of arrow- until stop tab engages on other side of retainer -2-.

  • Page 71: Brakes - Hydraulics

    Touareg 2010 ➤ Brake systems - Edition 05.2011 47 – Brakes - hydraulics Repairing front brake calipers Assembly overview - brake caliper, Brembo 17" ♦ When carrying out repairs, install all parts supplied in repair kit. ♦ Use only methylated spirits for cleaning the brake.

  • Page 72: Removing And Installing Piston For 17" And 18" Brembo Caliper

    Touareg 2010 ➤ Brake systems - Edition 05.2011 ♦ Use only methylated spirits for cleaning the brake. ♦ Apply thin coat of assembly paste -G 052 150 A2- to brake cylinder, piston and seal. 1 - Bleeder valve, 12 Nm ❑...
  • Page 73 Touareg 2010 ➤ Brake systems - Edition 05.2011 ♦ Wedge -3409- ♦ Piston resetting appliance -T10145- 1.3.1 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‐...
  • Page 74 Touareg 2010 ➤ Brake systems - Edition 05.2011 – Insert seal in brake caliper. – Place protective cap on piston. – Using equal pressure, push piston into brake caliper. The protective cap should locate securely in the groove. If not, use piston resetting tool to push piston in slightly.

  • Page 75: Repairing Rear Brake Calipers

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Repairing rear brake calipers Assembly overview - brake caliper, Brembo 17" ♦ When carrying out repairs, install all parts supplied in repair kit. ♦ Use only methylated spirits for cleaning the brake.
  • Page 76 Touareg 2010 ➤ Brake systems - Edition 05.2011 ♦ Wedge -3409- ♦ Piston resetting appliance -T10145- 2.2.1 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-.
  • Page 77 Touareg 2010 ➤ Brake systems - Edition 05.2011 – Insert oil seal in brake caliper housing. – Place protective cap on piston. – Using equal pressure, push piston into brake caliper housing. The protective cap should locate securely in the groove. If not, use piston resetting tool to push piston in slightly.

  • Page 78: Pressurised Leak Test

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Pressurised leak test Special tools and workshop equipment required ♦ Tester for brake pressure regulator -V.A.G 1310 A- ♦ Adapter M10 -V.A.G 1310/6- ♦ or ♦ Adapter M8 -V.A.G 1310/13- ♦ or ♦...

  • Page 79: Bleeding Brake System

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Bleeding brake system Bleeding the brake system is described using brake filling and bleeding equipment -VAS 5234- . WARNING Only use new brake fluid conforming to VW standard (VW 501 14). Note Do not under any circumstances allow brake fluid to come into ♦...
  • Page 80 Touareg 2010 ➤ Brake systems - Edition 05.2011 ♦ Brake filling and bleeding equipment -VAS 5234- ♦ Tool set for brake bleeding -VAS 6564- WARNING Only use new brake fluid conforming to VW standard (VW 501 14). 4.1.1 Bleeding (normal): Adhere strictly to work sequence when bleeding brake system.

  • Page 81: Changing Brake Fluid

    Touareg 2010 ➤ Brake systems - Edition 05.2011 ♦ in vehicles with EDL, EDL/TCS or EDL/TCD/ESP a chamber in the brake fluid reservoir is completely empty. This occurs e.g. in the case of brake system leaks. Subsequent bleeding requires the assistance of a second me‐...

  • Page 82: Assembly Overview - Brake Servo/Brake Master Cylinder

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Assembly overview - brake servo/brake master cylinder Note Use only new brake fluid. Observe information on brake fluid reservoir! I - All models II - Vacuum pump for brakes -V192- for hybrid models ⇒...

  • Page 83: Removing And Installing Brake Light Switch F , Left-Hand Drive

    Touareg 2010 ➤ Brake systems - Edition 05.2011 6 - Sealing ring 7 - Torx bolt, 5 Nm 8 - Clip 9 - Brake light switch -F- ❑ Removing and installing (LHD) ⇒ page 79 ❑ Removing and installing (RHD) ⇒...

  • Page 84: Removing And Installing Brake Light Switch F , Right-Hand Drive

    Touareg 2010 ➤ Brake systems - Edition 05.2011 – Unscrew securing bolts -arrows- and remove cover of con‐ nection and distribution box 2 -SX2- . – Disconnect all multi-pin connectors, depends on equipment installed. – Pull front wiring harness out of bulkhead and place as far as possible to side together with E-box.
  • Page 85 Touareg 2010 ➤ Brake systems - Edition 05.2011 – Insert brake light switch -F- -1- into clip on top of brake master cylinder and fit bolt. – Check function of brake light. Specified torque Component Specified torque Brake light switch -F- to brake master cylinder 5 Nm 5.

  • Page 86: Brake Servo Vacuum Supply

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Brake servo vacuum supply Overview - vacuum pump for brake ser‐ vo (diesel vehicles) Vacuum pump for 6-cyl. diesel engine: Must not be dismantled. Vacuum pump -2- Vacuum hose to brake servo -3- with non-return valve.
  • Page 87 Touareg 2010 ➤ Brake systems - Edition 05.2011 1 - Vacuum pump for brakes - V192- ❑ Location ⇒ page 83 ❑ Removing and installing ⇒ page 83 2 - Lower buffer 3 - Buffer 4 - Hexagon nut, 7 Nm...
  • Page 88 Touareg 2010 ➤ Brake systems - Edition 05.2011 Removing – Remove noise insulation ⇒ General body repairs, exterior; Rep. gr. 50 ; Noise insulation . – Release vacuum hose -A- and pull off -arrow-. – Unclip wiring harness from retainer -C- and lay to side.

  • Page 89: Removing And Installing Vacuum Line With Vacuum Sender G608 , Right-Hand Drive Model

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Removing and installing vacuum line with vacuum sender -G608- , right-hand drive model – Open clamp -1- and remove suction line. – Pull off engine compartment seal in vicinity of brake servo.

  • Page 90: Checking Brake Servo Vacuum System

    Touareg 2010 ➤ Brake systems - Edition 05.2011 – Pull vacuum line off separating point -arrow- by pressing re‐ lease buttons. – Pull vacuum line -1- out of brake servo unit. – Cover engine compartment in area of engine control unit - J623- , to prevent scratching of paintwork.
  • Page 91 Touareg 2010 ➤ Brake systems - Edition 05.2011 ♦ Vacuum pump (if there is one) When evaluating the measuring results, bear in mind that they will be influenced by the geographical location. The higher your lo‐ cation is above sea level, the lower the air pressure will be.
  • Page 92 Touareg 2010 ➤ Brake systems - Edition 05.2011 – Push hose -A- of brake servo vacuum gauge -VAS 6721- onto vacuum hose and press adapter -C- into brake servo. 6.4.2 Checking vacuum generation Note ♦ The average air pressure of the earth's atmosphere at sea level is 1013 mbar and decreases steeply as the altitude in‐...
  • Page 93 Touareg 2010 ➤ Brake systems - Edition 05.2011 6.4.3 Checking for leaks Note The average air pressure of the earth's atmosphere at sea ♦ level is 1013 mbar and decreases steeply as the altitude in‐ creases (approx. 100 mbar/1,000 m altitude). Local and time fluctuations also influence vacuum generation.

  • Page 94: Checking Non-Return Valve

    Touareg 2010 ➤ Brake systems - Edition 05.2011 – After generation of vacuum, close cut-off valve -A- in order to check brake servo vacuum system. Vacuum check in vicinity of non-return valve, vacuum hoses with connectors and vacuum pump/intake pipe: –...

  • Page 95: Removing And Installing Brake Master Cylinder

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Removing and installing brake mas‐ ter cylinder Removing and installing brake master cylinder, left-hand drive Special tools and workshop equipment required ♦ Brake filling and bleeding equipment -VAS 5234- 7.1.1 Removing – Remove left plenum chamber cover ⇒ General body repairs, exterior;...

  • Page 96: Removing And Installing Brake Master Cylinder, Right-Hand Drive Vehicle

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Observe the following important points when installing: – When assembling brake master cylinder with brake servo, make sure plunger rod is properly positioned in brake master cylinder. Sealing ring between brake master cylinder and brake servo is fitted.
  • Page 97 Touareg 2010 ➤ Brake systems - Edition 05.2011 7.2.1 Removing – Open clamp -1- and remove suction line. – Pull off engine compartment seal in vicinity of brake servo. – Remove right plenum chamber cover ⇒ General body repairs, exterior; Rep. gr. 50 ; Plenum chamber cover .
  • Page 98 Touareg 2010 ➤ Brake systems - Edition 05.2011 – Unclip brake line -1- from retainers -arrows-. – Unscrew brake lines from brake master cylinder -A- and -B-. – Seal brake lines and brake master cylinder using sealing plugs -1H0 698 311 A- from repair kit.
  • Page 99 Touareg 2010 ➤ Brake systems - Edition 05.2011 – Remove bolt -arrow- and remove brake fluid reservoir -1- from brake master cylinder -2-. – Remove nut -arrow-. – Carefully take brake master cylinder -1- off brake servo -2-. 7.2.2 Installing Install in reverse order.

  • Page 100: Removing And Installing Brake Servo

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Removing and installing brake servo Removing and installing brake servo, left-hand drive Special tools and workshop equipment required ♦ Brake filling and bleeding equipment -VAS 5234- 8.1.1 Removing – Remove left plenum chamber cover ⇒ General body repairs, exterior;...
  • Page 101 Touareg 2010 ➤ Brake systems - Edition 05.2011 – Unscrew brake lines -A and B- from brake master cylinder. – Seal brake lines and brake master cylinder using sealing plugs -1H0 698 311 A- from repair kit. – Pull vacuum hose out of brake servo.

  • Page 102: Removing And Installing Brake Servo, Right-Hand Drive Vehicle

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Removing and installing brake servo, right-hand drive vehicle Special tools and workshop equipment required ♦ Release tool -T10159 A- ♦ Sealing tool -T10249- ♦ Torque wrench -V.A.G 1331- ♦ Brake filling and bleeding equipment -VAS 5234- 8.2.1...
  • Page 103 Touareg 2010 ➤ Brake systems - Edition 05.2011 – Remove bolts -arrows- for coolant expansion tank -1-. – Slide coolant expansion tank -1- in -direction of arrow- out of retainer. – Place coolant expansion tank -1- to one side. Note Do not pull off coolant hoses.
  • Page 104 Touareg 2010 ➤ Brake systems - Edition 05.2011 – Unscrew brake lines from brake master cylinder -A- and -B-. – Seal brake lines and brake master cylinder using sealing plugs -1H0 698 311 A- from repair kit. – Release and pull connector -2- off brake light switch -F- -1-.
  • Page 105 Touareg 2010 ➤ Brake systems - Edition 05.2011 – Remove nut -arrow-. – Carefully take brake master cylinder -1- off brake servo -2-. – Remove footwell cover ⇒ General body repairs, interior; Rep. gr. 68 ; Compartments, covers and trims .

  • Page 106: Repairing Brake Lines

    Touareg 2010 ➤ Brake systems - Edition 05.2011 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 allows sections of brake lines to be renewed at less expense.

  • Page 107: Assembly Overview - Flanging Tool

    Touareg 2010 ➤ Brake systems - Edition 05.2011 Assembly overview - flanging tool 1 - Flanging tool upper part ❑ Unbolt to change flang‐ ing jaws 2 - Fastening for handle ❑ Must be removed to ac‐ cess retaining screw for...
  • Page 108 Touareg 2010 ➤ Brake systems - Edition 05.2011 – 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.
  • Page 109 Touareg 2010 ➤ Brake systems - Edition 05.2011 – Turn spindle to stop in flanging tool. – Turn spindle back again. – Loosen hexagon socket head bolts diagonally. – Remove brake line from flanging tool, clean and check brake line and flange.

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