VOLKSWAGEN GOLF VARIANT 2007 (18) PDF Document

The type of brake system installed in your vehicle is indicated by the corresponding PR number found on the vehicle data sticker. This sticker can be located in the spare wheel well and in the service schedule.

The brake test should be performed on a single-axle roller dynamometer with contra-rotating rollers. This prevents brake forces from being transferred to the drive train. If no such test rig is available, you may perform the test on a standard single-axle roller dynamometer as follows:

Step 1. Drive the vehicle forwards onto the rollers.

Step 2. Switch the engine off and wait for 2 seconds.

Step 3. Carry out the front brake test.

Step 4. Start the engine and wait for approximately 5 seconds until sufficient vacuum has been built up.

Step 5. Drive the vehicle forwards until the rear wheels are positioned on the rollers.

Step 6. Switch the engine off and wait for 2 seconds.

Step 7. Carry out the rear brake test.

Step 8. Start the engine and wait for approximately 5 seconds until sufficient vacuum has been built up.

Note: The maximum test speed must not exceed 6 km/h.

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

Absolute cleanliness is required. Do not use products containing mineral oil (e.g., oils, greases). Thoroughly clean all unions and adjacent areas before loosening. Do not use aggressive cleaning agents like brake cleanser, petrol, or thinners. Only use lint-free cloths. Place removed parts on a clean surface and cover them. When the system is open, do not work with compressed air and do not move the vehicle. Disconnect the battery earth strap with the ignition switched off before starting work.

If the brake pad warning lamp (-K32-) does not go out 3 seconds after the ignition is switched on or comes on during operation, the brake pads may be worn or there may be a wire fault. If the ABS warning lamp (-K47-) does not go out, the voltage supply may be low (below 10 volts), there may be a fault in the ABS, or a temporary speed sensor fault occurred. If both the ABS warning lamp (-K47-) and the brake system warning lamp (-K118-) light up, the ABS is defective. If only the brake system warning lamp (-K118-) remains on, the handbrake may be applied or the brake fluid level may be too low.

After replacing brake pads, depress the brake pedal firmly several times with the vehicle stationary so the pads are properly seated. Before removing the caliper, draw off brake fluid from the reservoir. When changing pads, do not disconnect the brake hose.

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 prevent damage to the brake hose.

Step 6. Remove the brake pads from the brake caliper.

Step 7. Thoroughly clean the brake carrier and contact surfaces, removing any corrosion.

Step 8. Before pressing the piston back, draw off brake fluid from the reservoir to prevent overflow.

Step 9. Press the piston back using a piston resetting tool.

Step 10. Insert the inner and outer brake pads with retaining springs into the brake caliper.

Step 11. Position the brake caliper and bolt it to the brake carrier with the guide pins.

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

Step 13. Fit wheels and check brake fluid level.

Adjustment is only necessary after renewing handbrake cables, brake calipers, or brake discs. First, depress the brake pedal forcefully at least three times, and pull the handbrake on three times and release it. With the lever in the rest position, tighten the adjusting nut until the lever at the brake calipers lifts off the stop (projection). The total distance to the stops on both calipers must not be less than or equal to 1.5 mm. Finally, verify that both wheels turn freely.

The technical specifications vary based on the brake system: