VOLKSWAGEN GOLF 2004 (12) PDF Document

The type of brake system installed in the vehicle is indicated by the corresponding PR number on the vehicle data sticker, which can be found in the spare wheel well and in the service booklet.

The brake test must be performed on a single-axle roller dynamometer. The maximum test speed must not exceed 6 km/h.

Before carrying out repair work, determine the cause of the fault as well as the control unit code using Guided Fault Finding. Disconnect the battery earth strap with the ignition switched off. Absolute cleanliness is required. Do not use products containing mineral oil. Thoroughly clean all unions before loosening. Place removed parts on a clean surface and cover. When the system is open, do not work with compressed air and do not move the vehicle. Only use genuine parts.

The following warning lamps provide information on the brake system:

Brake pad warning lamp (K32): If this lamp does not go out 3 seconds after ignition is switched on, or comes on during operation, the brake pads are likely worn or there is a wiring fault.

ABS warning lamp (K47): If this does not go out after the self-test, the voltage supply may be low, or there is a fault in the ABS.

ABS warning lamp (K47) and brake system warning lamp (K118): If both light up, the ABS may be defective. If only the brake system warning lamp (K118) remains on, the handbrake may be applied, the brake fluid level may be too low, or there is a fault in the warning lamp wiring.

Traction control system warning lamp (K86) or ESP and TCS warning lamp (K155): If these do not go out after the self-test, there is a fault affecting the TCS or ESP system.

Step 1. Remove the wheels.

Step 2. Disconnect the connector for the brake pad wear indicator.

Step 3. Remove the cover caps.

Step 4. Unscrew both guide pins and remove them from the brake caliper.

Step 5. Remove the brake caliper and secure it with wire to avoid straining the brake hose.

Step 6. Take the brake pads out of the brake caliper.

Step 7. Clean the brake carrier and contact surfaces, removing any corrosion. Do not use compressed air.

Step 8. Press the piston back into the cylinder using a piston resetting tool. Ensure brake fluid is drawn off from the reservoir first.

Step 9. Insert the new inner and outer brake pads with retaining springs.

Step 10. Position the brake caliper with brake pads onto the brake carrier.

Step 11. Bolt the brake caliper to the brake carrier using the guide pins. Tighten to 30 Nm.

Step 12. Fit cover caps and reconnect the brake pad wear indicator connector.

Step 13. After installation, firmly depress the brake pedal several times to seat the pads properly.

New adjustment is only necessary after renewing handbrake cables and brake calipers.

Step 1. Remove the center console components required to access the adjustment nut.

Step 2. Depress the foot brake hard at least three times.

Step 3. Firmly pull on and then release the handbrake three times.

Step 4. Tighten the adjusting nut until the lever lifts off the brake caliper stop. The total distance to the stops on both left and right calipers must not exceed 1.5 mm.

Step 5. Check that both wheels turn freely.

Step 1. Cut through the brake line at a suitable point using a pipe cutter.

Step 2. Clamp the brake line tightly in a set of grips, leaving approximately 50 mm projecting.

Step 3. Use a brake line scraper in a drill at slow speed to scrape the coating off the brake line.

Step 4. Slide the union bolt onto the brake line.

Step 5. Slide the brake line into the flanging tool until it reaches the stop.

Step 6. Tighten the brake line in the flanging tool, then tighten the hexagon socket head bolts diagonally.

Step 7. Turn the spindle to the stop in the flanging tool and then turn it back.

Step 8. Remove the brake line, clean it, and check the flange.

Step 9. Join the brake lines using a connector.

Step 10. Bleed the brake system.