Brake And Clutch System, Changing Brake Fluid: Notes

WARNING:

Brake fluid must never come into contact with fluids containing mineral oils (oil, gas, cleaning solutions). Oils containing minerals damage seals and rubber grommets on brake systems.
Brake fluid is poisonous. Do not let brake fluid come in contact with the paint due to is corrosive effects.
Brake fluid is hygroscopic, which means that it absorbs moisture from the air. Always store brake fluid in air-tight containers.
Wash off any spilled brake fluid with plenty of water.
Follow all disposal regulations.

CAUTION:

Use only Brake Fluid VW 501 14:B 000 750 in this vehicle.

Special Tools And Workshop Equipment Required

Mini Torque Wrench:VAS6854

Fig 1: Identifying Mini Torque Wrench VAS 6854
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Brake Filling and Bleeding Equipment:VAS6860

Fig 2: Identifying Brake Charger/Bleeder Unit
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Brake Filling and Bleeding Equipment:VAS6860

Fig 3: Brake Filling and Bleeding Equipment :VAS6860
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Brake Bleeding Tool Set:VAS6564

Fig 4: Identifying Tool Set : VAS6564 For Brake Bleeding
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Bleeder Hose:VAG1238B3

Brake Fluid, Extracting

-- Remove the cap -1- from the brake fluid reservoir.

Fig 5: Identifying Brake Fluid Reservoir Cap

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-- Insert the suction hose from the Brake Charger/Bleeder Unit through the screen -1- in the brake fluid reservoir to extract as much brake fluid -2- as possible.

Fig 6: Suction Hose From The Brake Charger/Bleeder Unit

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NOTE:

Do not remove the screen inside the brake fluid reservoir.

After extracting, observe that no further brake fluid runs into the reservoir (the brake fluid level in the reservoir must align with the lower edge of the screen).

Attach the brake charger/bleeder unit:

NOTE:

The bleed hose must fit tightly over the bleed screw to prevent air from getting into the brake system.

The brake fluid level in the reservoir must be high enough so that air cannot get into the brake system.

For RHD vehicles, begin with the right front.

-- Attach the adapter -1- to the brake fluid reservoir.

Fig 7: Identifying Screw Adapter

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-- Attach the hose from the Brake Filling and Bleeding Equipment to the adapter -1-.

-- Set the correct pressure on the Brake Charger/Bleeder Unit (refer to the Owner's Manual) and switch on the Brake Charger/Bleeder Unit.

Front Axle

-- Remove the cap -1- from the bleed screw on the left front brake caliper.

Fig 8: Identifying Bleeder Screw Cap

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-- Connect the collector bottle bleed hose -1- to the left front bleeder valve.

Fig 9: Identifying Collector Bottle Bleeder Hose

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-- Open the breather valve and let the corresponding quantity of brake fluid drain out. Refer to Sequence and Brake Fluid Capacity Table .

-- Close the bleeder screw. Tightening specification. Refer to item 2) OVERVIEW - FRONT BRAKE CALIPER (BLEEDER SCREW/VALVE) .

-- Reattach the brake caliper bleeder screw cap.

-- Repeat the steps on the front right side.

Rear Axle

-- If necessary, remove both wheels from the rear axle in order to access the bleeder valve.

-- Remove the cap -1- on the left rear brake caliper breather valve.

Fig 10: Identifying Bleeder Screw Cap (Rear)

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-- Guide the bleeder hose -1- from the Brake Bleeding Tool Set:VAS6564 from the inside of the rim through the socket -3- and connect to the bleed screw.

Fig 11: Bleeding Rear Brakes

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-- Open the breather valve and let the corresponding quantity of brake fluid drain out. Refer to Sequence and Brake Fluid Capacity Table .

-- Close the bleeder valve. For the tightening specification, refer to item 12) OVERVIEW - REAR BRAKE CALIPER - BLEEDER SCREW / VALVE .

-- Install the cap on the left rear brake caliper bleed valve.

-- Repeat the same procedure on the right rear side of the vehicle.

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-- Remove the dust cap from the breather valve -arrow-.

-- Connect the bleed hose and connect the pressure hose with the collector bottle.

Use the Bleed Hose (670 mm long):VAG1238/B3 if necessary to bleed.

-- Open the breather valve.

-- Allow approximately 100 ml brake fluid to escape.

-- Close the bleeder valve.

-- Push the clutch pedal quickly from stop to stop 10 to 15 times.

-- Open the breather valve.

-- Allow another 50 ml brake fluid to escape.

-- Close the breather valve and install the dust cap.

Tightening Specification	Nm
Breather valve	4.5

-- After completing the bleeding procedure press the clutch pedal several times.

-- Switch off the Brake Charger/Bleeder Unit.

-- Install the air filter housing in reverse order of removal.

-- Remove the filler hose from the adapter.

-- Remove the adapter from the brake fluid reservoir.

-- Check the brake fluid level and correct if necessary. It must be between -1- and -2-.

Fig 12: Identifying Brake Fluid Level Marks On Reservoir

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-- Screw on the brake fluid reservoir cap -1-.

Fig 13: Identifying Brake Fluid Reservoir Cap

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-- Install the rear wheel if necessary.

-- Perform a function test during the test drive.