Skoda Kodiaq 2017 Workshop Manual
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Skoda Kodiaq 2017 Workshop Manual

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Service
Workshop Manual
Kodiaq 2017 ➤
Kodiaq 2019 ➤
Brake systems
Edition 11.2018
Service Department. Technical Information

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Summary of Contents for Skoda Kodiaq 2017

  • Page 1 Service Workshop Manual Kodiaq 2017 ➤ Kodiaq 2019 ➤ Brake systems Edition 11.2018 Service Department. Technical Information...
  • Page 2 Service List of Workshop Manual Repair Groups R e p a i r G r o u p 00 - Technical data 45 - Anti-lock brake system 46 - Brakes - mechanism 47 - Brakes - hydraulics 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.

  • Page 3: Table Of Contents

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Contents 00 - Technical data ........... .
  • Page 4 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Brake pedal ............

  • Page 5: Technical Data

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 00 – Technical data Safety instructions (SRL001300; Edition 11.2018) ⇒ “1.1 Safety precautions when working on vehicles with start- stop system”, page 1 ⇒ “1.2 Safety precautions during road tests in which testing and measuring equipment is used”, page 1...

  • Page 6: Identification

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Identification ⇒ “2.1 PR number assignment – brake”, page 2 PR number assignment – brake The brake type installed in the vehicle is indicated by PR num‐ bers.

  • Page 7: Technical Data

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Technical data ⇒ “3.1 Technical data for brakes”, page 3 Technical data for brakes ⇒ “3.1.1 Master brake cylinder and brake servo”, page 3 ⇒ “3.1.2 Front brakes”, page 3 ⇒...
  • Page 8 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Front brake caliper (type denomination) C 60 (16") PR number Pad thickness without supporting plate m Minimum pad thickness without sup‐ porting plate Front brake C 60 Front brake caliper (type denomination) C 60 (17")
  • Page 9 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Rear brake caliper (type denomination) FNc-M42 (17”) PR number Brake disc, minimum thickness Pad thickness without supporting plate m Minimum pad thickness without sup‐ porting plate 3.1.4 Brake fluid...
  • Page 10 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Classification Only use new original brake fluid N.052.766.Z0 as per US standard FMVSS 571.116, DOT 4 and VW standard 501 14 Top-up ⇒ Maintenance ; Booklet Kodiaq...

  • Page 11: Brake Inspection

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Brake inspection ⇒ “4.1 General points”, page 7 ⇒ “4.2 Checking vehicles with front-wheel drive”, page 7 ⇒ “4.3 Testing vehicles with four-wheel drive”, page 7 ⇒ “4.4 Check the parking brake”, page 8 General points ♦...

  • Page 12: Check The Parking Brake

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Start engine and wait approx. 5 seconds until adequate vac‐ uum has built up. Check the parking brake ⇒ “4.4.1 Check electromechanical parking brake, vehicles with front drive”, page 8 ⇒...
  • Page 13 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Enabled »MOT mode« is signalled by the yellow Electric parking and handbrake fault lamp - K214- lighting up. Note The electromechanical parking brake does not fully close in »MOT mode«...

  • Page 14: Anti-Lock Brake System

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 45 – Anti-lock brake system General points ⇒ “1.1 Repair instructions for repair work on ABS”, page 10 Repair instructions for repair work on The ABS brake system is split diagonally. Brake servo assistance is provided pneumatically by the vacuum brake servo.
  • Page 15 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 The ABS control unit - J104- -1- and the ABS hydraulic unit - N55- -2- form a single unit. They can only be separated after the complete unit is removed. The ABS control unit - J104- can be separated from the ABS hydraulic unit - N55- ⇒...
  • Page 16 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 ♦ The valve coils in the ABS control unit - J104- must not be calibrated. ♦ The valve coils in the ABS control unit - J104- cannot be re‐...

  • Page 17: Installation Location Overview

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Installation location overview ⇒ “2.1 ABS/ESP installation location overview”, page 13 ABS/ESP installation location overview Note If the ABS hydraulic unit - N55- is damaged, the ABS control unit - J104- must be fully replaced with the ♦...
  • Page 18 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 2 - Front right wheel speed sensor - G45- ❑ Check ⇒ Vehicle diagnostic tester ❑ Removing and installing ⇒ “4.6 Removing and installing front speed sensors G45 / G47 ”, page 43 3 - Switch module 1 in centre console - EX23- ❑...

  • Page 19: Control Unit And Hydraulic Unit

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Control unit and hydraulic unit ⇒ “3.1 Exploded view – control unit and hydraulic unit”, page 15 ⇒ “3.2 Removing and installing ABS control unit J104 / ABS hy‐...
  • Page 20 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 1 - ABS control unit - J104- ❑ Removing and installing ⇒ “3.2 Removing and in‐ stalling ABS control unit J104 / ABS hydraulic unit N55 ”, page 19 ❑...
  • Page 21 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 9 - Brake line ❑ from master brake cylinder (floating piston circuit) to ABS hydraulic unit - N55- ❑ Distinguishing feature: ∅ 6 mm and pipe screw with long thread M12 x 1 ❑...

  • Page 22: Exploded View - Control Unit And Hydraulic Unit

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 3.1.2 Exploded view – control unit and hydraulic unit, right-hand drive vehicle Note Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after ♦...

  • Page 23: Removing And Installing Abs Control Unit J104 / Abs Hydraulic Unit N55

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 7 - ABS hydraulic unit - N55- with ABS control unit - J104- ❑ Removing and installing ⇒ “3.2 Removing and installing ABS control unit J104 / ABS hydraulic unit N55 ”, page 19 ❑...
  • Page 24 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 ♦ Repair kit - 1H0 698 311 A- Removing Fitting location: The ABS control unit - J104- is bolted to the ABS hydraulic unit - N55- and is located in the engine compartment on the right side.
  • Page 25 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Position brake pedal load , e.g. -V.A.G 1869/2- . – Attach the bleeder hose of the bleeding bottle onto the vent valves of the front left and rear left brake caliper and open vent valves.
  • Page 26 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Mark both brake lines -5- and -6- from the master brake cyl‐ inder and unscrew from the ABS hydraulic unit - N55- . – Close the brake lines and threaded holes immediately with plugs from the repair kit - 1H0 698 311 A- .

  • Page 27: Hand Drive Vehicle

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Tightening sequence of the brake lines Tightening torques - summaries of components Note Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.
  • Page 28 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Fit engine support bracket - T10533- to gearbox and assembly carrier as per figure (N23-10646). – Press the engine with gearbox forwards using the support bracket - T10533- .
  • Page 29 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Position brake pedal load , e.g. -V.A.G 1869/2- . – Attach the bleeder hose of the bleeding bottle onto the vent valves of the front left and rear left brake caliper and open vent valves.

  • Page 30: Abs Hydraulic Unit - N55

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Remove mounting bracket -arrows- in the vehicle from the ABS hydraulic unit - N55- . – Lay the ABS hydraulic unit - N55- with the ABS control unit - J104- facing downwards in the engine compartment.
  • Page 31 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Tightening sequence of the brake lines Tightening torques - summaries of components Note Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.
  • Page 32 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 The ABS control unit - J104- is bolted to the ABS hydraulic unit - N55- and is located in the engine compartment on the right side. Note Do not bend the brake lines in the area of the hydraulic unit.
  • Page 33 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Position brake pedal load , e.g. -V.A.G 1869/2- . – Attach the bleeder hose of the bleeding bottle onto the vent valves of the front left and rear left brake caliper and open vent valves.
  • Page 34 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Fit engine support bracket - T10533- to gearbox and assembly carrier as per figure (N23-10646). – Press the engine with gearbox forwards using the support bracket - T10533- .
  • Page 35 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Tightening sequence of the brake lines Tightening torques - summaries of components Note Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.
  • Page 36 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Unlock the fuse plug -1- in direction of arrow -A- and pull it off the ABS control unit - J104- in direction of arrow -B-. Note The illustration shows the hydraulic unit for ABS - N55- with con‐...
  • Page 37 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Pull the ABS hydraulic unit - N55- and the ABS control unit - J104- -1- in the -direction of the arrow- and out of the shock absorbers.

  • Page 38: Disconnecting The Control Unit From The Hydraulic Unit

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Tightening sequence of the brake lines Tightening torques - summaries of components Note Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.

  • Page 39: Fitting The Control Unit To The Hydraulic Unit

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Separate the ABS control unit - J104- from the ABS hydraulic unit - N55- in the -direction of arrow-. Note The ABS control unit - J104- may not tilt when it is pulled off from the ABS hydraulic unit - N55- .

  • Page 40: Connecting Brake Lines To Hydraulic Unit

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Start by bolting the ABS control unit - J104- to the ABS hy‐ draulic unit - N55- by hand using new screws -arrows-. Note A new ABS control unit - J104- may only be installed on the ♦...
  • Page 41 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 On the ABS hydraulic unit - N55- A - Primary piston circuit of brake master cylinder to ABS hy‐ draulic unit - N55- - Distinguishing feature: ∅ 6 mm and pipe screw with thread M 12 B - Secondary piston circuit of brake master cylinder to ABS hy‐...
  • Page 42 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 On the ABS hydraulic unit - N55- A - Primary piston circuit of brake master cylinder to ABS hy‐ draulic unit - N55- - Distinguishing feature: ∅ 6 mm and pipe screw with thread M 12 B - Secondary piston circuit of brake master cylinder to ABS hy‐...

  • Page 43: Sensors

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Sensors ⇒ “4.1 Assembly overview - speed sensor on front axle”, page 39 ⇒ “4.2 Assembly overview - speed sensor on rear axle”, page 41 ⇒ “4.3 Removing and installing the brake pressure sender”, page ⇒...
  • Page 44 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 1 - Front speed sensor - G45- / -G47- ❑ Assignment ⇒ Electron‐ ic Catalogue of Original Parts ❑ clean the inner surface of the hole before insert‐...

  • Page 45: Assembly Overview - Speed Sensor On Rear Axle

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Assembly overview - speed sensor on rear axle ⇒ “4.2.1 Summary of components - speed sensors on rear axle, vehicles with front-wheel drive”, page 41 ⇒ “4.2.2 Summary of components - speed sensors on rear axle, vehicles with four-wheel drive”, page 42...

  • Page 46: Removing And Installing The Brake Pressure Sender

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 4.2.2 Summary of components - speed sensors on rear axle, vehicles with four- wheel drive Note Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.

  • Page 47: Removing And Installing The Handbrake Switch

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Removing and installing the handbrake switch The handbrake switch is integrated into a housing with the vehi‐ cle's central locking switch ⇒ Electrical system; Rep. gr. 96 ;...
  • Page 48 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Disconnect plug -1- on the rear speed sensor - G44- / -G46- . – Remove screw -2-. – Pull the rear speed sensor - G44- / -G46- out of the axle stud and brake carrier.

  • Page 49: Brakes - Mechanism

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 46 – Brakes - mechanism Front brakes ⇒ “1.1 Assembly overview - front brakes”, page 45 ⇒ “1.2 Removing and installing brake pads, front brake”, page 47 ⇒ “1.3 Removing and installing brake caliper, front brake”, page 51 ⇒...
  • Page 50 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 1 - Cover plate ❑ Removing and installing ⇒ “1.5 Removing and in‐ stalling brake shield plates, front brake”, page 55 ❑ Assignment ⇒ Electron‐ ic Catalogue of Original...

  • Page 51: Removing And Installing Brake Pads, Front Brake

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 9 - Screw ❑ clean when using again ❑ 200 Nm 10 - Wheel bearing housing ❑ with bolted brake carrier ❑ Assignment ⇒ Electronic Catalogue of Original Parts 11 - Brake hose ❑...
  • Page 52 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Note Observe the instructions for changing the pad ♦ ⇒ “1.2.1 Changing the brake pads of the front brake - Mounting instructions”, page 47 When removing mark the brake pads (inner, outer) you intend ♦...
  • Page 53 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Remove the brake caliper -1- and secure with wire in such a way that the weight of the brake caliper does not burden or damage the brake hose Note Do not disconnect the brake line.
  • Page 54 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Press the piston into the brake caliper using the piston reset‐ ting jig - T10145- . – Lightly grease guiding surface for brake pads on brake carrier with grease from the repair kit.

  • Page 55: Removing And Installing Brake Caliper, Front Brake

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – If available, connect plug connection -1- for the brake pad wear indicator. – Attach the wheels. Note After each brake pad replacement, forcefully apply the brake ♦...
  • Page 56 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Insert brake pedal load, , e.g. -V.A.G 1869/2- . – Press down brake pedal with brake pedal load , e.g. -V.A.G 1869/2- , at least 60 mm.
  • Page 57 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Press the piston into the brake caliper using the piston reset‐ ting jig - T10145- . – Lightly grease guiding surface for brake pads on brake carrier with grease from the repair kit.

  • Page 58: Removing And Installing Brake Discs, Front Brake

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Mount plug connection -1- for brake pad wear indicator. – Screw the brake line onto the brake caliper. – Remove brake pedal load , e.g. -V.A.G 1869/2- .

  • Page 59: Removing And Installing Brake Shield Plates, Front Brake

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Remove the screw -arrow- and take off the brake disc. Installing Installation is carried out in the reverse order. When installing, observe the following: – Clean the surfaces for the brake disc and wheel hub.

  • Page 60: Rear Brakes

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Rear brakes ⇒ “2.1 Assembly overview - rear brakes”, page 56 ⇒ “2.2 Removing and installing brake pads”, page 58 ⇒ “2.3 Removing and installing brake caliper, rear brake”, page 62 ⇒...
  • Page 61 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 1 - Cover plate ❑ Removing and installing ⇒ “2.5 Removing and in‐ stalling brake shield plate”, page 67 ❑ Assignment ⇒ Electron‐ ic Catalogue of Original Parts 2 - Screw ❑...

  • Page 62: Removing And Installing Brake Pads

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 ❑ Observe the instructions for changing the pad ⇒ “2.2.1 Changing the brake pads of the rear brake - Mounting instructions”, page 58 11 - Spring ❑ Only on inner brake pad ❑...
  • Page 63 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Check and clean the brake piston as well as the brake caliper, replace sealing sleeve and protective cap. Replace the brake caliper completely if damaged. 2.2.2 Removing and installing brake pads,...
  • Page 64 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Lever the retaining spring -1- for the brake pads out of the brake caliper -arrow- with a screwdriver -A-. – Remove caps -arrows-. – Remove both guide pins with extension (No. 7) - T10503- from the brake caliper.
  • Page 65 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Remove brake pads -2- and -3-. Clean WARNING Do not flush the brake system with compressed air. The dust that is generated is hazardous to health! – Thoroughly clean guiding surface for brake pads on brake carrier and remove corrosion.

  • Page 66: Removing And Installing Brake Caliper, Rear Brake

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Insert inner -2- and outer -3- brake pads into the brake carrier. – Attach the brake caliper -1- and guide pin with extension (No. 7) - T10503- to the brake carrier.
  • Page 67 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 ♦ Vehicle diagnosis, measurement and information system ♦ Brake filling and bleeding device , e. g. -VAS 5234- ♦ Brake pedal load , e.g. -V.A.G 1869/2- ♦ Extension piece (No. 7) - T10503- ♦...
  • Page 68 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Insert brake pedal load, , e.g. -V.A.G 1869/2- . – Press down brake pedal with brake pedal load , e.g. -V.A.G 1869/2- , at least 60 mm.
  • Page 69 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Remove caps -arrows-. – Remove both guide pins from the brake caliper with extension (No. 7) - T10503- . – Pull off brake caliper from brake carrier.

  • Page 70: Removing And Installing Brake Disc

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Note Check brake fluid level, if necessary top up with brake fluid. Tightening torques - summaries of components Note Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.

  • Page 71: Removing And Installing Brake Shield Plate

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Removing and installing brake shield plate Removing – Remove brake disc ⇒ “2.4 Removing and installing brake disc”, page 66 For vehicles with closed heat protection plate – Removing wheel hub ⇒ Chassis, axles, steering; Rep. gr. 42 ;...

  • Page 72: Handbrake

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Handbrake ⇒ “3.1 Assembly overview - parking brake”, page 68 ⇒ “3.2 Removing and installing control unit for electronic hand‐ brake J540 ”, page 69 ⇒ “3.3 Removing and installing handbrake motor V282 / V283 ”,...

  • Page 73: Removing And Installing Control Unit For Electronic Handbrake J540

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 4 - Sealing ring ❑ Replace after disassembly 5 - Parking motor on the left - V282- ❑ Fitting location: on rear left brake caliper ❑ Removing and installing ⇒...
  • Page 74 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Take out sealing ring. Note Make sure that the annular groove of the sealing ring and the contact surface of the handbrake motor are not damaged. – Clean the annular groove and the contact surface of the hand‐...

  • Page 75: Brake Pedal

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Brake pedal ⇒ “4.1 Assembly overview - brake pedal”, page 71 ⇒ “4.2 Removing and installing bearing bracket”, page 75 ⇒ “4.3 Separating brake pedal from brake servo”, page 79 ⇒...
  • Page 76 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 1 - Bearing bracket ❑ Removing and installing ⇒ “4.2 Removing and in‐ stalling bearing brack‐ et”, page 75 2 - Nut ❑ self-locking ❑ Replace after disas‐...
  • Page 77 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Order of tightening 4.1.2 Summary of components - brake pedal, right-hand drive WARNING The brake pedal travel must not be restricted by additional floor coverings. Note Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after ♦...
  • Page 78 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 1 - Screw ❑ 20 Nm 2 - Bearing bracket ❑ Removing and installing ⇒ “4.2 Removing and in‐ stalling bearing brack‐ et”, page 75 3 - Nut ❑...

  • Page 79: Removing And Installing Bearing Bracket

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 9 - Bearing shell 10 - Support ❑ for ball head of pressure rod of brake servo unit 11 - Bushing Note Note installation position. 12 - Cap Removing and installing bearing bracket ⇒...
  • Page 80 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Disconnect plug -2- from the control unit for variable front light‐ ing. – Remove screw -1- and open the footwell covering -2- in -direction of arrow-. – Remove the accelerator pedal ⇒ Rep. gr. 20 ; throttle control .
  • Page 81 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Release the nuts -1- to -4-. – Detach all the electrical cables from the bearing bracket. – Remove bracket. Installing Installation is carried out in the reverse order. When installing, observe the following: –...
  • Page 82 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Disconnect plug -2- from the control unit for variable front light‐ ing. – Disconnect wiring loom -2- from bearing bracket -1-. – Separating the brake pedal from the brake servo unit ⇒...

  • Page 83: Separating Brake Pedal From Brake Servo

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Install the electric wiring harness -2- so that it is not then trap‐ ped between pedal and bearing bracket. Tightening torques - summaries of components Note Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.

  • Page 84: Clipping The Brake Pedal Onto The Brake Servo Unit

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Clipping the brake pedal onto the brake servo unit – Hold ball head of push rod in front of mount and push brake pedal in direction of brake servo, so that the ball head clicks into place.
  • Page 85 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Unscrew bearing bolt against -direction of the arrow-. The fuses -A- break off. Continued for all vehicles – Pull out bearing bolt. – Remove brake pedal. Installing Note Replace bearing bolt with screw for bearing bolt.

  • Page 86: Brakes - Hydraulics

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 47 – Brakes - hydraulics Front brake calipers ⇒ “1.1 Summary of components - front brake caliper”, page 82 ⇒ “1.2 Removing and installing brake caliper piston”, page 83...

  • Page 87: Removing And Installing Brake Caliper Piston

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 8 - Piston ❑ Removing and installing ⇒ “1.2 Removing and installing brake caliper piston”, page 83 9 - Sealing ring ❑ Removing and installing ⇒ “1.2 Removing and installing brake caliper piston”, page 83 10 - Brake caliper ❑...
  • Page 88 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Position the protective cap with the outer sealing lip on the piston. – Insert inner sealing lip of the protective cap with disassembly wedge - 3409- in the groove of the cylinder.

  • Page 89: Rear Brake Caliper

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Rear brake caliper ⇒ “2.1 Summary of components - rear brake caliper”, page 85 ⇒ “2.2 Removing and installing protective cover”, page 86 Summary of components - rear brake caliper...

  • Page 90: Removing And Installing Protective Cover

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 13 - Dust cap Removing and installing protective cov‐ Special tools and workshop equipment required ♦ Piston jig - T10145- ♦ Assembly tool - T10146- ♦ Plastic wedge - 3409- Removing Only the protective cover always has to be replaced.
  • Page 91 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Fit protective cover into the groove -arrow- on the piston. – Screw in piston in -direction of arrow-. – Press the protective cover with the piston resetting tool -...

  • Page 92: Brake Servo Unit And Master Brake Cylinder

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Brake servo unit and master brake cylinder ⇒ “3.1 Summary of components - brake servo unit and master brake cylinder”, page 88 ⇒ “3.2 Removing and installing brake light switch”, page 93 ⇒...

  • Page 93: Brake Cylinder

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 1 - Nut ❑ self-locking ❑ Replace after disas‐ sembly ❑ Observe tightening se‐ quence ⇒ Fig. ““Order of tighten‐ ing”“ , page 73 ❑ Tightening torque ⇒ “4.1.1 Summary of components - brake pedal, left-hand drive”,...
  • Page 94 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 13 - Vacuum line ❑ Assignment ⇒ Electronic Catalogue of Original Parts ❑ Non-return valve (in vacuum hose); Functional test ⇒ “4.2 Checking the non-return valve”, page 113 ❑...
  • Page 95 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 3.1.2 Summary of components - brake servo unit/master brake cylinder, right- hand drive vehicles Note Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.
  • Page 96 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 ❑ Removing and installing ⇒ “3.4.3 Removing and installing master brake cylinder, right-hand drive vehicles”, page 108 ❑ Assignment ⇒ Electronic Catalogue of Original Parts 11 - Brake light switch -F - ❑...

  • Page 97: Removing And Installing Brake Light Switch

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Removing and installing brake light switch ⇒ “3.2.1 Removing and installing brake light switch, left-hand drive vehicles”, page 93 ⇒ “3.2.2 Removing and installing brake light switch, right-hand drive vehicles”, page 94...
  • Page 98 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – The brake light switch - F- -1- must be in contact with the edge -arrow- of the brake master cylinder. Tightening torques - summaries of components Note Replace bolts / nuts that are tightened at an angle of rotation, as well as replacement components after removal.

  • Page 99: Removing And Installing Brake Servo

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Removing and installing brake servo ⇒ “3.3.1 Removing and installing brake booster, left-hand drive, except for Bi-Turbo diesel engine”, page 95 ⇒ “3.3.2 Removing and installing brake booster, left-hand drive with Bi-Turbo diesel engine”, page 96...
  • Page 100 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Release the nuts -3- and -4-. – Carefully remove the brake servo unit from the vehicle. Installing Installation is carried out in the reverse order. When installing, observe the following: –...
  • Page 101 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Pull vacuum hose -1- out of brake servo -2-. – Unscrew the nuts -arrows B-. – Remove holder -1- on gearbox bearing -3-. – Unlock coolant lines -4- on bracket -arrow A- and remove.
  • Page 102 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Release the nuts -3- and -4-. – Carefully remove the brake servo unit from the vehicle. Installing Installation is carried out in the reverse order. When installing, observe the following: –...
  • Page 103 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Note Observe safety precautions when working on the air conditioning system and working with the refrigerant. – Remove refrigerant lines ⇒ Heating, Air Conditioning; Rep. gr. 87 ; Refrigerant circuit; Removing and installing the refrig‐...
  • Page 104 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Release fixing nuts -arrows-. – Remove the brake servo unit downwards out of the vehicle. Installing Installation is carried out in the reverse order. When installing, observe the following: –...
  • Page 105 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Remove refrigerant lines ⇒ Heating, Air Conditioning; Rep. gr. 87 ; Refrigerant circuit; Removing and installing the refrig‐ erant lines with inner heat exchanger . Note To prevent the intrusion of moisture, all components of the refrig‐...

  • Page 106: Removing And Installing Master Brake Cylinder

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Release fixing nuts -arrows-. – Lower front axle with steering gear to service position ⇒ Run‐ ning gear, axles, steering; Rep. gr. 40 ; Assembly carrier; lower assembly carrier .
  • Page 107 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Note The master brake cylinder must not be repaired. ♦ Assignment ⇒ Electronic Catalogue of Original Parts . ♦ Removing – Remove engine trim panel where present ⇒ Rep. gr. 10 ;...
  • Page 108 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Detach the return hose -B- of the clutch master cylinder from the brake fluid reservoir and attach it slightly higher. Continued for all vehicles – If present, disconnect the plug -1- from the brake light switch, - F- the plug -2- from the vacuum sensor - G608- and the plug -3- from the brake fluid level warning contact - F34- .

  • Page 109: Summary Of Components - Brake Servo Unit/Master Brake

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Mark brake lines -1-. – Unscrew the brake lines -1- at the master brake cylinder, close the brake lines with the screw plugs from the repair kit - 1H0 698 311 A- .
  • Page 110 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Note The master brake cylinder must not be repaired. ♦ Assignment ⇒ Electronic Catalogue of Original Parts . ♦ Removing – Disconnect battery earth strap ⇒ Electrical system; Rep. gr.
  • Page 111 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Use brake filling and bleeding device , e.g. -VAS 5234- , to extract as much brake fluid as possible with the extraction bottle from the brake fluid reservoir.

  • Page 112: Cylinder, Left-Hand Drive Vehicles

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Mark brake lines -1-. – Unscrew the brake lines -1- at the master brake cylinder, close the brake lines with the screw plugs from the repair kit - 1H0 698 311 A- .
  • Page 113 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Use brake filling and bleeding device , e.g. -VAS 5234- , to extract as much brake fluid as possible with the extraction bottle from the brake fluid reservoir.
  • Page 114 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Removing body-bound rivet -3-. – Pull the brake fluid reservoir -2- out of the plugs. – Remove plug -2- from the brake light switch - F- -1- and re‐...

  • Page 115: Check The Operation Of The Brake Servo Unit

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Mark brake lines -2-. – Unscrew the brake lines -2- at the master brake cylinder -1-, close the brake lines with the screw plugs from the repair kit - 1H0 698 311 A- .
  • Page 116 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 If the brake servo unit operates perfectly the brake pedal must yield noticeably under your foot after starting the engine (servo boost takes effect). Replace faulty brake servo units ⇒...

  • Page 117: Vacuum System

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Vacuum system ⇒ “4.1 Exploded view – vacuum pump”, page 113 ⇒ “4.2 Checking the non-return valve”, page 113 ⇒ “4.3 Removing and installing vacuum sensor G608 ”, page 113 ⇒...

  • Page 118: Checking The Vacuum System

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Removing – If necessary, disconnect intake hose -1-. – Disconnect plug -3- for vacuum sensor - G608- -1-. – Pull vacuum hose out of brake servo. – Carefully lever the vacuum sender - G608- -1- out of the vac‐...
  • Page 119 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 The measuring results will be influenced by the geographical lo‐ cation. The higher the location is above sea level, the lower the air pressure will be. Take note of the following test requirements: ♦...
  • Page 120 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 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 121 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Open locking valve -A-. – Close cut-off valves -B+C-. – Start warm engine (> 60°C), press accelerator briefly (engine speed greater than 2000/min). Normally (see notes), the vacuum that is generated should be between 600 and 950 mbar (depending on engine size).
  • Page 122 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 4.4.5 Vacuum generation with manual vac‐ uum pump - VAS 6213- Special tools and workshop equipment required ♦ Hand vacuum pump - VAS 6213- Instead of vacuum generation by means of engine or vacuum pump, the vacuum can be generated with the manual vacuum pump - VAS 6213- in certain cases.

  • Page 123: Brake Lines

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Brake lines ⇒ “5.1 Repairing brake lines”, page 119 Repairing brake lines ⇒ “5.1.1 Assembly overview - Flaring tool”, page 119 ⇒ “5.1.2 Work instruction”, page 120 5.1.1...
  • Page 124 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 1 - Flaring tool upper part ❑ unscrew for changing the flaring chucks 2 - Attachment for door handle ❑ must be unscrewed to access securing bolt for...
  • Page 125 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 NOTICE ♦ Brake fluid must never come into contact with fluids contain‐ ing mineral oils (oil, petrol, cleaning agent, because the fluids damage the sealing rings and boots of the brake system.
  • Page 126 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Clamp the brake line in the gripping pliers -4- tight enough, so that it protrudes approx. 50 mm out of the plastic chuck jaws. – Tension the peeler -3- in a boring machine and place it onto the brake line.
  • Page 127 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 – Assemble the brake lines together with the connecting piece -E-. – Install brake line. – Bleeding Brake System ⇒ “6.3 Bleeding hydraulic system following standard proce‐ dure”, page 125...

  • Page 128: Hydraulic System

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Hydraulic system ⇒ “6.1 General notes on brake fluid”, page 124 ⇒ “6.2 Prebleeding the hydraulic system”, page 124 ⇒ “6.3 Bleeding hydraulic system following standard procedure”, page 125 ⇒...

  • Page 129: Bleeding Hydraulic System Following Standard Procedure

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 A pre-pressure of 0,2 MPa (2 bar) is required to bleed the brake system. – Unscrew cap -1- from the brake fluid reservoir – Connect the thread plug -1- of the brake filling and bleeding device e.g.
  • Page 130 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 A pre-pressure of 0,2 MPa (2 bar) is required to bleed the brake system. – Unscrew cap -1- from the brake fluid reservoir – Connect the thread plug -1- of the brake filling and bleeding device e.g.

  • Page 131: Subsequent Bleeding Of Hydraulic System

    Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 Subsequent bleeding of hydraulic sys‐ Special tools and workshop equipment required ♦ Brake filling and bleeding device , e. g. - VAS 5234- ♦ Tool set for brake bleeding - VAS 6564- ♦...
  • Page 132 Kodiaq 2017 ➤ , Kodiaq 2019 ➤ Brake systems - Edition 11.2018 sure loss must not exceed 0.4 MPa (4 bar). If the loss of pressure is higher, replace the master brake cylinder. – Separate brake system tester e.g. - V.A.G 1310A- .

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