Volkswagen Workshop Service and Repair Manuals

• Brake fluid reservoir cap
• Brake fluid reservoir
• Sealing plugs
• Primary piston circuit brake pipe
• ◆ Connecting on ABS vehicles
  =>Page 45-26.
• ◆ Connecting on ABS/EDL vehicles
  =>Page 45-26.

• Secondary piston brake pipe
• ◆ Connecting on ABS vehicles =>Page 45-26.
• ◆ Connecting on ABS/EDL vehicles =>Page 45-26.

• Nut; 25 Nm
• Tandem brake master cylinder
• Sealing ring
• Brake pedal position sender
• ◆ Removing and installing
  => Page 45-29
• ◆ Checking

=> Running gear - self-diagnosis; Repair group 01

• Spacer cap
• ◆ Various versions => Page 45-29
• Sealing ring
• ◆ Renew
• Circlip
• ◆ Renew
• Brake servo
• Push rod
• Brake pedal
• Brake light switch
• Gasket
• Hexagon nut, 25 Nm

• Bracket
• Heat shield
• Clip
• Supply pipe
• ◆ Brake fluid reservoir to brake master cylinder secondary piston circuit
• ◆ Connecting => Fig.3.
• Supply pipe
• ◆ Brake fluid reservoir to master brake cylinder primary piston circuit
• ◆ Connecting => Fig.3.

• Hexagon nut, 25 Nm
• Heat shield

• Mounting bush
• Buffer
• Brake pipe
• ◆ Hydraulic unit to front right brake caliper
• Brake pipe
• ◆ Hydraulic unit to rear left brake caliper
• Brake pipe
• ◆ Hydraulic unit to rear right brake caliper
• Brake pipe
• ◆ Hydraulic unit to front left brake caliper

• ABS or ABS/EDL hydraulic unit
• ◆ Removing and installing
  => Page 45-26
• Mounting bracket
• Gasket
• Reinforcing plate
• Hexagon nut, 25 Nm

Connecting brake pipes from tandem master cylinder to hydraulic unit

→ Fig.1    Vehicles with ABS

•     A -    Secondary piston circuit
•     B -    Primary piston circuit

→ Fig.2    Vehicles with ABS/EDL

•     A -    Secondary piston circuit
•     B -    Primary piston circuit
•     1 -    Hydraulic unit to front right brake caliper
•     2 -    Hydraulic unit to rear left brake caliper
•     3 -    Hydraulic unit to rear right brake caliper
•     4 -    Hydraulic unit to front left brake caliper

→ Fig.3    Connecting supply pipes to hydraulic unit and reservoir

•     A -    Secondary piston circuit
• Colour coding: green
• Connect smaller diameter to top fitting on reservoir
•     B -    Primary piston circuit
• Colour coding: yellow
• Connect larger diameter to bottom fitting on reservoir

Notes.

• ◆ The supply pipe connections to the hydraulic unit have different diameters.
• ◆ Colour coding on supply pipes -arrows- correspond to the colour coding of the hydraulic unit connections.
• ◆ The supply pipes must be fitted as far as the stops on the hydraulic unit connections and at least 17 mm onto the reservoir connections.
• ◆ First fit supply pipes to hydraulic unit, clip into retainer and then fit onto reservoir connection.