Mechanical Components: Other Volkswagen Eos I

CI 38 REAR BRAKES, SERVICING

Note. After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position. Use brake charger/bleeder unit VAS 5234 or extraction device V.A.G 1869/4 to extract brake fluid from brake fluid reservoir. Before removing brake caliper or disconnecting brake hose, brake pedal actuator V.A.G 1869/2 must be inserted (this dissipates pressure).

Scheme 64

1. ABS Wheel Speed Sensor Before inserting sensor, clean inner surface of bore hole and coat with hot bolt paste G 052 112 A3
2. Hex Socket Head Bolt 8 Nm
3. Multi-Point Socket Head Bolt Always replace after removing it. 90 Nm plus an additional 90° turn
4. Wheel Bearing Housing
5. Cover Plate
6. Bolts Hex Head Bolt, 9 Nm Torx® Bolt, 12 Nm Hex head screw M6x10 changed from Torx® screw M6x12 Replace hex head bolt with hex head bolt and Torx® bolt with Torx® bolt
7. Wheel Bearing/Hub Unit
8. Brake Rotor Diameter: 255 mm Thickness: 10 mm Wear limit: 8 mm Always replace pads on both sides of axle if worn. Remove brake caliper before removing
9. Bolt 4 Nm
10. Bolt
11. Brake Pads Thickness 11 mm without backing plate Wear limit: 2 mm without backing plate Checking thickness, refer to «MAINTENANCE PROCEDURES»(ref-475587-S15524971022012052300000) Must always be replaced together on both sides of axle Removing and installing, refer to «BRAKE PADS»(ref-475622-S13135046152012052300000)
12. Brake Carrier with Guide Pins and Protective Cap Supplied as an assembled replacement part with sufficient grease on guide pins If protective caps or guide pins are damaged, install repair kit. Use supplied grease packet to lubricate guide pins
13. Brake Caliper Do not remove brake hose when replacing brake pad Removing and installing, refer to «BRAKE CALIPER»(ref-475622-S05372015362012052300000) Servicing, refer to «CI 38, CII 38 CII 41 BRAKE CALIPERS, REAR BRAKE CALIPER OVERVIEW»(ref-475557-S22401208622012052300000) After servicing or replacing, parking brake cable must be adjusted first. Adjusting the parking brake, refer to «PARKING BRAKE, ADJUSTING»(ref-475622-S15911456972012052300000)
14. Hose Retainer
15. Brake Line 14 Nm
16. Hex Bolt, Self-Locking Replace 35 Nm
17. Parking Brake Cable Adjusting the parking brake, refer to «PARKING BRAKE, ADJUSTING»(ref-475622-S15911456972012052300000)
18. Spring Clamp
19. Brake Hose

CII 41 REAR BRAKES, SERVICING

Note. After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position. Use brake charger/bleeder unit VAS 5234 or extraction device V.A.G 1869/4 to extract brake fluid from brake fluid reservoir. Before removing brake caliper or disconnecting brake hose, brake pedal actuator V.A.G 1869/2 must be inserted (this dissipates pressure).

I - Front Wheel Drive Assembly Overview

II - All Wheel Drive Differences

Scheme 65

1. ABS Wheel Speed Sensor Before inserting sensor, clean inner surface of bore hole and coat with hot bolt paste G 052 112 A3
2. Hex Socket Head Bolt 8 Nm
3. Multi-Point Socket Head Bolt Always replace after removing it. 90 Nm plus an additional 90° turn Removing and installing with socket T10035 (Scheme 67)
4. Wheel Bearing Housing
5. Cover Plate
6. Bolts Hex head bolt: 9 Nm Torx® bolt: 12 Nm Hex head bolt M6x10 changed from Torx® bolt M6x12 Replace hex head bolt with hex head bolt and Torx® bolt with Torx® bolt
7. Wheel Bearing/Hub Unit
8. Brake Rotor Diameter 15 inch: 260 mm, 16 inch: diameter 286 mm, 17 inch: diameter 310 mm Thickness 15 and 16 inches: 12 mm, 17 inches: 22 mm Wear limit 15 and 16 inches: 10 mm, 17 inches: 20 mm Always replace pads on both sides of axle if worn. Remove brake caliper before removing
9. Bolt 4 Nm
10. Bolt Only on front wheel drive
11. Brake Pads Thickness: 11 mm without backing plate Wear limit: 2 mm without backing plate Checking thickness, refer to «MAINTENANCE PROCEDURES»(ref-475587-S15524971022012052300000) Must always be replaced together on both sides of axle Removing and installing, refer to «BRAKE PADS»(ref-475622-S17308184332012052300000)
12. Brake Carrier with Different Guide Pins and Protective Cap Supplied as an assembled replacement part with sufficient grease on guide pins If protective caps or guide pins are damaged, install repair kit. Use supplied grease packet to lubricate guide pins Assembly guide (Scheme 66)
13. Anti-Rattle Spring Always replace when pads are replaced
14. Brake Caliper Do not remove brake hose when replacing brake pad Removing and installing, refer to «BRAKE CALIPER»(ref-475622-S29904662682012052300000) Servicing, refer to «CI 38, CII 38 CII 41 BRAKE CALIPERS, REAR BRAKE CALIPER OVERVIEW»(ref-475557-S22401208622012052300000) After servicing or replacing, parking brake cable must be adjusted first. Adjusting the parking brake, refer to «PARKING BRAKE, ADJUSTING»(ref-475622-S15911456972012052300000)
15. Hose Retainer
16. Brake Line 14 Nm
17. Hex Bolt, Self-Locking Replace 35 Nm
18. Parking Brake Cable Adjusting the parking brake, refer to «PARKING BRAKE, ADJUSTING»(ref-475622-S15911456972012052300000)
19. Spring Clamp
20. Brake Hose

Scheme 66

1. Short guide pins with stepping -arrows-, inlet side.
2. Longer guide pins, outgoing.
3. Vibration dampener, outgoing.

Scheme 67

PARKING BRAKE, ADJUSTING

The parking brake must be adjusted after replacing the parking brake cable and the brake caliper.

Depending on the center console version, either remove only the cupholder, the rear cover or the entire center console. Refer to Removal and Installation .

Operate brake pedal forcefully at least three times.

Engage the parking brake three times and release it.

The parking brake lever must go back into the rest position by itself under the first detent.

1. Parking brake lever in released position.

Tighten adjustment nut -arrow (close-up)-...

Scheme 68

...until levers -1- on brake calipers lift off from stop -2-.

Scheme 69

The distance -a- to the stop -2- on the left and right brake caliper must not exceed 1.5 mm together.

Check whether wheels turn freely.

Due to the automatic rear brake adjuster, there is no need to adjust the parking brake after making initial adjustment.

Scheme 70

1. Parking Brake Lever Remove center console before removing.
2. Hex Nut 15 Nm
3. Trim for Parking Brake Lever Pull off forward Pry off release tab in rear bottom handle area -arrow- with a screwdriver With a leather version, leather in catch area is cut.
4. Relay Rod
5. Compensator Bracket
6. Adjustment Nut Adjusting the parking brake, refer to «PARKING BRAKE, ADJUSTING»(ref-475622-S15911456972012052300000)
7. Parking Brake Cables Removing and installing, through MY 2007, refer to «PARKING BRAKE CABLE, THROUGH MY 2007»(ref-475622-S37414043902012052300000) Removing and installing, from MY 2008, refer to «PARKING BRAKE LEVER, FROM MY 2008»(ref-475622-S09522520382012052300000)
8. Parking Brake Switch

BRAKE PADS

Special tools and workshop equipment required

1. Torque Wrench 5-50 Nm V.A.G 1331
2. Piston Resetting Tool T10145

Removing

When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven!

Remove wheels.

Using screwdriver, pry off brake pad retaining spring from brake caliper -arrow- and remove.

Scheme 71

Separate the connector -1- for brake pad wear indicator.

Scheme 72

Remove caps -arrows-.

Scheme 73

Loosen both guide pins -arrows- and remove from brake caliper.

Scheme 74

Remove brake caliper and secure with wire so that the weight of the brake caliper does not burden or damage the brake hose.

Remove brake pad from brake caliper or from brake carrier.

Cleaning

Thoroughly clean contact surfaces for brake pads at brake carrier, remove corrosion.

Clean brake caliper, especially the adhesive surface for the brake pad, it must be free of residual adhesive and grease.

Use only appropriate solvents for cleaning brake caliper.

Installing

Before pressing piston into cylinder using piston resetting tool, brake fluid must be extracted from brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.

Press piston back.

Scheme 75

Remove protective foil on backing plate of outer brake pad.

Install outer brake pad on brake carrier.

Insert inner brake pad with retaining spring in brake caliper (piston).

When installing brake caliper, make sure that brake pad is not affixed to brake caliper before the correct installation position has been reached.

Do not damage the adhesion surface.

Tighten brake caliper to brake carrier using both guide pins.

Install both protective caps.

Install retaining spring in brake caliper.

Connect brake pad wear indicator connector.

Install wheels.

Tightening specification for wheel bolts. Refer to WHEEL BOLT TIGHTENING SPECIFICATION

Note. After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position. Check brake fluid level after replacing brake pad.

BRAKE CALIPER

Special tools and workshop equipment required

1. Torque Wrench 5-50 Nm V.A.G 1331
2. Brake Pedal Actuator V.A.G 1869/2

Removing

Work procedure applies only for replacing or when performing subsequent service work on brake caliper.

Remove wheels.

Using screwdriver, pry off brake pad retaining spring from brake caliper and remove.

Separate the connector for brake pad wear indicator.

Connect bleeder hose of bleeder bottle to bleeder valve of brake caliper and then open bleeder valve.

Insert V.A.G 1869/2.

Close bleeder valve and remove bleeder bottle.

Remove the brake hose.

Pull both cover caps from bushings of brake caliper.

Loosen both guide pins and remove from brake caliper.

Pull off brake caliper from brake carrier.

Remove brake pads from brake caliper.

Installing

1. Piston is pressed back.
2. Outer brake pad sits on brake carrier.

Insert inner brake pad with retaining spring in brake caliper (piston).

When installing brake caliper, make sure that brake pad is not affixed to brake caliper before the correct installation position has been reached.

Do not damage the adhesion surface.

Tighten brake caliper to brake carrier using both guide pins.

Install both protective caps.

Screw brake hose on brake caliper.

Remove V.A.G 1869/2.

Install retaining spring in brake caliper.

Connect brake pad wear indicator connector.

Bleed brake system. Refer to BRAKE SYSTEM, BLEEDING

Install wheels.

Tightening specification for wheel bolts. Refer to WHEEL BOLT TIGHTENING SPECIFICATION .

Note. Before moving vehicle, depress brake pedal several times firmly to properly seat brake pads in their normal operating position. Check brake fluid level.

Special tools and workshop equipment required

1. Torque Wrench 50-50 Nm V.A.G 1331
2. Resetting & Extracting Tool T10165

Removing

When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven!

Remove wheels.

Counter-hold guide pins and remove attachment bolts from brake caliper.

Scheme 76

Remove brake caliper and secure with wire so that the weight of the brake caliper does not burden or damage the brake hose.

Remove brake pads.

Cleaning

Thoroughly clean contact surfaces for brake pads at brake carrier, remove corrosion.

Clean brake caliper, especially the adhesive surfaces for the brake pads, they must be free of residual adhesive and grease.

Use only appropriate solvents for cleaning brake caliper.

Installing

Before pushing back the piston, extract some of the brake fluid out of the brake fluid reservoir using a bleeder bottle. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.

Install pistons at knurled wheel on T10165 by turning toward right. Do not damage protective caps.

Use special tool T10165/1 for assistance when installing.

Scheme 77

1. For pistons that are difficult to move, an open-end wrench (size 13 mm) can be applied at the appropriate wrench surface -arrow A-.

Remove protective foil on brake pad backing plates.

Insert brake pads in brake carrier.

Scheme 78

When installing brake caliper, make sure that brake pads are not affixed to brake caliper before the correct installation position has been reached.

Secure brake caliper using new self-locking bolts.

1. The repair kit includes four self-locking hex bolts which must be installed in all cases.

Install wheels.

Tightening specification for wheel bolts. Refer to WHEEL BOLT TIGHTENING SPECIFICATION .

Note. After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position. Check brake fluid level after replacing brake pad.

Special tools and workshop equipment required

1. Torque Wrench 5-50 Nm V.A.G 1331
2. Brake Pedal Actuator V.A.G 1869/2

Removing

Work procedure applies only for replacing or when performing subsequent service work on brake caliper.

Remove wheels.

Unhook the brake cable from the lever on the brake caliper.

Remove the spring clip and pull the brake cable from the holder on the brake caliper.

Connect bleeder hose of bleeder bottle to bleeder valve of brake caliper and then open bleeder valve.

Insert V.A.G 1869/2.

Close bleeder valve and remove bleeder bottle.

Remove the brake line.

Remove both bolts from brake caliper, counter hold on guide pin when doing this.

Pull off brake caliper from brake carrier.

Installing

1. Piston is pressed back.
2. Brake pads sit on the brake carrier.

Secure brake caliper on brake carrier using new self-locking bolts.

Screw brake line on brake caliper.

Bleed brake system. Refer to BRAKE SYSTEM, BLEEDING

Hook in the brake cable and secure it to the holder with the spring clip.

Adjusting the parking brake, refer to PARKING BRAKE, ADJUSTING

Install wheels.

Tightening specification for wheel bolts. Refer to WHEEL BOLT TIGHTENING SPECIFICATION .

Note. Before moving vehicle, depress brake pedal several times firmly to properly seat brake pads in their normal operating position. Check brake fluid level.

Special tools and workshop equipment required

1. Torque Wrench 5-50 Nm V.A.G 1331
2. Resetting & Extracting Tool T10165

Removing

When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven!

Remove wheels.

Counter-hold guide pins and remove attachment bolts from brake caliper.

Scheme 79

Remove brake caliper and secure with wire so that the weight of the brake caliper does not burden or damage the brake hose.

Remove brake pads and anti-rattle springs -arrows-.

Scheme 80

Cleaning

Contact surfaces between brake pads and brake carrier must be cleaned, remove corrosion.

Clean brake caliper.

Use only appropriate solvents for cleaning brake caliper.

Installing

Before pushing back the piston, extract some of the brake fluid out of the brake fluid reservoir using a bleeder bottle. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.

Install pistons at knurled wheel on T10165 by turning toward right. Do not damage protective caps.

Use special tool 10165/1 for assistance when installing.

1. For pistons that are difficult to move, an open-end wrench (size 13 mm) can be applied at the appropriate wrench surface -arrow A-.

Insert brake pad retention plates -arrows- and brake pads in brake carrier.

Make sure that the brake pads are located correctly in the anti-rattle springs -arrows-.

Scheme 81

Secure brake caliper using new self-locking bolts.

1. The repair kit includes four self-locking hex bolts which must be installed in all cases.

Install wheels.

Tightening specification for wheel bolts. Refer to WHEEL BOLT TIGHTENING SPECIFICATION .

Note. After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position. Check brake fluid level after replacing brake pad.

Special tools and workshop equipment required

1. Torque Wrench 5-50 Nm V.A.G 1331
2. Brake Pedal Actuator V.A.G 1869/2

Removing

Work procedure applies only for replacing or when performing subsequent service work on brake caliper.

Remove wheels.

Unhook the brake cable from the lever on the brake caliper.

Remove the spring clip and pull the brake cable from the holder on the brake caliper.

Connect bleeder hose of bleeder bottle to bleeder valve of brake caliper and then open bleeder valve.

Insert V.A.G 1869/2.

Close bleeder valve and remove bleeder bottle.

Remove the brake line.

Remove both bolts from brake caliper, counterhold on guide pin when doing this.

Pull off brake caliper from brake carrier.

Installing

1. Piston is pressed back.
2. Brake pads sit in retaining springs on the brake carrier.

Secure brake caliper on brake carrier using new self-locking bolts.

Screw brake line on brake caliper.

Bleed brake system. Refer to BRAKE SYSTEM, BLEEDING

Hook in the brake cable and secure it to the holder with the spring clip.

Adjusting the parking brake, refer to PARKING BRAKE, ADJUSTING

Install wheels.

Tightening specification for wheel bolts. Refer to WHEEL BOLT TIGHTENING SPECIFICATION .

Note. Before moving vehicle, depress brake pedal several times firmly to properly seat brake pads in their normal operating position. Check brake fluid level.

Special tools and workshop equipment required

1. Torque Wrench 5-50 Nm V.A.G 1331
2. Resetting & Extracting Tool T10165

Removing

When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven!

Remove wheels.

Counter-hold guide pins and remove attachment bolts from brake caliper.

Scheme 82

Remove brake caliper and secure with wire so that the weight of the brake caliper does not burden or damage the brake hose.

Remove brake pads and anti-rattle springs -arrows-.

Scheme 83

Cleaning

Contact surfaces between brake pads and brake carrier must be cleaned, remove corrosion.

Clean brake caliper.

Use only appropriate solvents for cleaning brake caliper.

Installing

Before pushing back the piston, extract some of the brake fluid out of the brake fluid reservoir using a bleeder bottle. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.

Install pistons at knurled wheel on T10165 by turning toward right. Do not damage protective caps.

Use special tool 10165/1 for assistance when installing.

1. For pistons that are difficult to move, an open-end wrench (size 13 mm) can be applied at the appropriate wrench surface -arrow A-.

Insert brake pad retention plates -arrows- and brake pads in brake carrier.

Make sure that the brake pads are located correctly in the anti-rattle springs -arrows-.

Scheme 84

Secure brake caliper using new self-locking bolts.

1. The repair kit includes four self-locking hex bolts which must be installed in all cases.

Install wheels.

Tightening specification for wheel bolts. Refer to WHEEL BOLT TIGHTENING SPECIFICATION .

Note. After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position. Check brake fluid level after replacing brake pad.

Special tools and workshop equipment required

1. Torque Wrench 5-50 Nm V.A.G 1331
2. Brake Pedal Actuator V.A.G 1869/2

Removing

Work procedure applies only for replacing or when performing subsequent service work on brake caliper.

Remove wheels.

Unhook the brake cable from the lever on the brake caliper.

Remove the spring clip and pull the brake cable from the holder on the brake caliper.

Connect bleeder hose of bleeder bottle to bleeder valve of brake caliper and then open bleeder valve.

Insert V.A.G 1869/2.

Close bleeder valve and remove bleeder bottle.

Remove the brake line.

Remove both bolts from brake caliper, counter-hold on guide pin when doing this.

Pull off brake caliper from brake carrier.

Installing

1. Piston is pressed back.
2. Brake pads sit in retaining springs on the brake carrier.

Secure brake caliper on brake carrier using new self-locking bolts.

Screw brake line on brake caliper.

Bleed brake system. Refer to BRAKE SYSTEM, BLEEDING

Hook in the brake cable and secure it to the holder with the spring clip.

Adjusting the parking brake, refer to PARKING BRAKE, ADJUSTING

Install wheels.

Tightening specification for wheel bolts. Refer to WHEEL BOLT TIGHTENING SPECIFICATION .

Note. Before moving vehicle, depress brake pedal several times firmly to properly seat brake pads in their normal operating position. Check brake fluid level.

PARKING BRAKE CABLE, THROUGH MY 2007

Removing

Release parking brake.

Remove center console. Refer to Removal and Installation .

Loosen adjustment nut -1- far enough until respective parking brake cable -2- can be disengaged from compensator bracket -3-.

Scheme 85

Pry off spring clip -1-.

Scheme 86

Press lever on brake caliper -2- in direction of -arrow- and disengage brake cable -3-.

Remove the Torx® bolt -1- and then loosen mounting clip from parking brake cable -2-.

Scheme 87

Disengage parking brake cable from bracket -1- and pull hand brake cable out of guide tube -2-.

Scheme 88

Installing

Slide parking brake cable into guide tube -2- and engage it in bracket -1-.

Press the lever on brake caliper -2- in direction of -arrow- and hook in the brake cable -3-.

Press spring clip -1- onto parking brake cable.

Parking brake cable -2- must be installed free of tension between bracket on brake caliper and mounting clip.

Therefore, only now screw mounting clip -1- onto longitudinal control arm.

Engage parking brake cable -2- into compensator bracket -3-.

Pre-load parking brake cable using adjustment nut -1-.

Adjust parking brake. Refer to PARKING BRAKE, ADJUSTING .

PARKING BRAKE LEVER, FROM MY 2008

Removing

Release parking brake.

Remove center console. Refer to Removal and Installation .

Loosen adjustment nut -1- far enough until respective parking brake cable -2- can be disengaged from compensator bracket -3-.

Press lever on brake caliper -2- in direction of -arrow- and disengage brake cable -3-.

Scheme 89

Press the retaining tabs together -1- and remove the parking brake cable from the bracket on the brake caliper.

Remove the parking brake cable -1- from the clamping tabs first and then completely from the bracket -2-.

Scheme 90

Disengage parking brake cable from bracket -1- and pull hand brake cable out of guide tube -2-.

Installing

Slide parking brake cable into guide tube -2- and engage it in bracket -1-.

Insert the parking brake cable -1- through the opening and then clamp it on the bracket -2-.

Press the parking brake cable through the bracket on the brake caliper until both retaining tabs -1- engage.

Press the lever on brake caliper -2- in direction of -arrow- and hook in the brake cable -3-.

The parking brake cable must be installed without tension between the bracket on the brake caliper and the bracket on the trailing arm.

Engage parking brake cable -2- into compensator bracket -3-.

Pre-load parking brake cable using adjustment nut -1-.

Adjust parking brake. Refer to PARKING BRAKE, ADJUSTING .

BRAKE PEDAL AND BRAKE BOOSTER

Special tools and workshop equipment required

1. Release Tool T10159

Removing

Remove trim on driver side. Refer to Removal and Installation .

Only on vehicles with brake lamp switch on mounting bracket

Disconnect connector from brake lamp switch.

Remove brake lamp switch by turning 45° to left.

Procedure for all vehicles

First press brake pedal in direction of brake booster and hold.

Scheme 91

2 - Pressure rod

3 - Retaining lugs

Insert T10159 and pull in direction of driver seat. When doing this, counter-hold on brake pedal. (At this moment the pedal must not be allowed to move backward). The mounting retaining lugs -3- will thereby be pressed off the ball head of the push rod -2-.

For ease of illustration separating the brake pedal from the brake booster is shown with the pedal assembly removed.

Pull T10159 and brake pedal together toward the driver seat. (The brake pedal will thereby be pulled off the ball head of the push rod).

Installing

Hold ball head of push rod in front of mounting and push brake pedal in direction of brake booster, so the ball head engages audibly.

Scheme 92

Further installation is in the reverse sequence to removal.

Only on vehicles with brake light switch on mounting bracket

Brake lamp switch, installing. Refer to .