Volkswagen Golf / Golf GTI / Golf Variant. Manual - part 800

– Turn the spindle all the way in the flange unit.
– Turn the spindle back.
– Loosen the hex socket head bolts diagonally.
– Remove the brake line from the flanging tool, clean the brake

line and the flared head and check.

Briefly rinse part of brake line remaining in vehicle:
– Connect the Brake Charger/Bleeder Unit - VAS5234- , place

the bleeder container hose on the flared head of the brake line

and run the Brake Charger/Bleeder Unit - VAS5234- briefly

until some brake fluid runs through.

– Clean the brake line with compressed air.

– Join brake lines with connecting piece -E-.
– Assemble brake line.
– Bleed the brake system. Refer to

⇒ “6.2 Hydraulic System, Standard Bleeding”, page 132

 .

6

Hydraulic System

⇒ “6.1 Brake Fluid General Information”, page 132
⇒ “6.2 Hydraulic System, Standard Bleeding”, page 132
⇒ “6.3 Hydraulic System, Post-Bleeding”, page 133
⇒ “6.4 Checking for Leaks”, page 133

6.1

Brake Fluid General Information

WARNING

Only use new brake fluid conforming to VW standard (VW 501

14).

Note

♦

Brake fluid is poisonous. Due to its caustic nature, it must also

never come in contact with paint.

♦

Brake fluid is hygroscopic, meaning that it absorbs moisture

from the surrounding air, and must therefore be stored in air-

tight containers.

♦

Rinse any spilled brake fluid with plenty of water.

Brake Fluid, Changing
Refer to ⇒ Maintenance ; Booklet  36.1 ; Procedure Descriptions;

Brake and Clutch System, Changing Brake Fluid .

6.2

Hydraulic System, Standard Bleeding

Special tools and workshop equipment required
♦ Brake Charger/Bleeder Unit - VAS5234-
♦ Brake Bleeding Tool Set - VAS6564-

Note

♦

The bleeding of hydraulic system using the Brake Charger/

Bleeder Unit - VAS5234- is described.

♦

A positive pressure of 2 bar (29 psi) required to bleed the ABS

Hydraulic Unit - N55- .

– Remove the rear wheels on vehicles with 15" rims.
Adhere strictly to work sequence when bleeding brake system.
– Connect the Brake Charger/Bleeder Unit - VAS5234-
– Open the bleeder valves in the specified sequence and bleed

the brake calipers.

1- Front left brake caliper
2 - Right front brake caliper
3 - Left rear brake caliper
4 - Right rear brake caliper

Use suitable bleeder hose. It must fit tightly on bleeder valve so

that no air gets into brake system.
– Vehicles with bleeder bottle hose attached, leave bleeder

valve open long enough that brake fluid exits without bubbles.

6.3

Hydraulic System, Post-Bleeding

Perform a post-bleeding when:
♦ The brake pedal travel is too long, or the so-called soft brake

pedal

A second technician is required during the post-bleeding.
– Connect the Brake Charger/Bleeder Unit - VAS5234-
– Press brake pedal forcefully and hold.
– Open bleeder valve at brake caliper.
– Press brake pedal down onto stop.
– Close bleeder valve with pedal depressed.
– Release brake pedal slowly.

Note

This bleeding procedure must be performed five times per brake

caliper.

Bleeding sequence:
1- Front left brake caliper
2 - Right front brake caliper
3 - Left rear brake caliper
4 - Right rear brake caliper

Note

A road test must be performed after bleeding. During this, at least

one ABS regulation must be performed!

6.4

Checking for Leaks

Special tools and workshop equipment required
♦ Brake Pressure Gauge - VAG1310A-
♦ Brake Pressure Gauge - Adapter M10 - VAG1310/6-
Test Prerequisites
• Brake system ( ABS Hydraulic Unit - N55- , brake hoses, brake

lines and brake calipers) operating properly and free of leaks.

Checking
– Remove the bleeder valve at one front brake caliper.
– Attach and bleed the Brake Pressure Gauge - VAG1310A- .
– Apply pressure to brake pedal until the gauge indicates a

pressure of 50 bar (725 psi). The pressure must not drop by

more than 4 bar (58 psi) during the test period of 45 seconds.

Replace master cylinder if pressure drops greatly.

7

Special Tools

Special tools and workshop equipment required
♦ Brake Caliper Tool - T10165-

♦ Sealing Tool - T10249-

♦ Brake Pressure Gauge - VAG1310A-

♦ Brake Pressure Gauge - Adapter M10 - VAG1310/6-
♦ Torque Wrench 1331 5-50Nm - VAG1331-