VOLKSWAGEN GOLF PLUS 2005 (07) PDF Document

The type of brake system installed in your vehicle is indicated among other things by the corresponding PR number found on the vehicle data sticker. This sticker is typically located in the spare wheel well and in your service booklet.

When working on the anti-lock brake system, you must observe the following precautions:

1. Determine the cause of the fault and control unit code using Guided Fault Finding before starting repairs.

2. Disconnect the battery earth strap with the ignition switched off.

3. Note the safety requirements for any welding work using an electric welding unit.

4. Observe all safety precautions when handling brake fluid.

5. Bleed the brake system if it had to be opened.

6. Maintain absolute cleanliness. Do not use products containing mineral oil, such as oils or greases.

7. Thoroughly clean all unions and adjacent areas before loosening. Avoid aggressive cleaning agents like brake cleanser, petrol, or thinners.

8. Use transport protection for contact pins after separating the control unit and hydraulic unit.

9. Do not use compressed air or move the vehicle when the system is open.

10. Do not touch contact surfaces on connectors, pressure sensors, or the control unit, and do not touch the silicone gel with your hands or objects.

11. During painting operations, ensure the electronic control unit is not exposed to excessive temperatures.

For a VOLKSWAGEN GOLF PLUS 2005 with front-wheel drive, the brake test must be performed on a single-axle roller dynamometer. The maximum test speed must not exceed 6 km/h. Ensure the manual gearbox is in neutral or the automatic transmission is in N before starting.

If both the ABS warning lamp and the brake system warning lamp light up, the ABS is defective. A change in braking behavior is to be expected, and it is possible that the rear wheels may lock up earlier than normal during braking.

To replace front brake pads on an FS III system, follow these steps:

1. Remove the wheels and disconnect the brake pad wear indicator connector.

2. Remove the cover caps.

3. Unscrew both guide pins and remove the brake caliper. Support the caliper with wire so it does not strain the brake hose.

4. Take the old brake pads out.

5. Thoroughly clean the brake carrier and contact surfaces, removing all corrosion. Clean the brake caliper housing using only methylated spirits.

6. Press the piston back using a piston resetting tool. Ensure you have drawn off excess brake fluid from the reservoir first to prevent overflow.

7. Insert the new inner brake pad (with large 3-finger clip) and outer brake pad (with small black 3-finger clip) with retaining springs.

8. Position the brake caliper onto the brake carrier.

9. Bolt the caliper to the carrier with the guide pins (30 Nm torque).

10. Fit the cover caps and reconnect the wear indicator.

11. Firmly depress the brake pedal several times while the vehicle is stationary to seat the pads properly.

The technical specifications for the FS III front brakes are as follows:

To bleed the brake system, you should use brake filling and bleeding equipment like the VAS 5234 or V.A.G 1869. Adhere to the following sequence:

1. Bleed the front left and front right brake calipers simultaneously.

2. Bleed the rear left and rear right brake calipers simultaneously.

Leave the bleeder valves open with the hoses connected until the brake fluid flows out free of air bubbles. A road test must be conducted after bleeding, during which an ABS regulation must be performed at least once.

New adjustment is only necessary after replacing handbrake cables or brake calipers. Follow these steps:

1. Remove the center console components required to access the mechanism.

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

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

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