Brake And Clutch System, Changing Brake Fluid: Notes

Special tools and workshop equipment required

Mini Torque Wrench: VAS 6854

Fig 1: Identifying Mini Torque Wrench VAS 6854
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Brake Filling and Bleeding Equipment: VAS 6860

Fig 2: Brake Filling and Bleeding Equipment : VAS6860
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Brake Bleeding Tool Set - Insert Tool: VAS 6564/9

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Brake Bleeding Tool Set: VAS 6564

Fig 3: Identifying Tool Set : VAS6564 For Brake Bleeding
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CAUTION:

Risk of injury of the skin due to corrosive brake fluid.

Irritation and injury of the skin possible.

- Avoid contact with skin.

CAUTION:

Risk of damaging the vehicle due to corrosive brake fluid.

Paint and vehicle damage possible.

- Prevent contact with components and paint. If necessary, rinse off leaking brake fluid with water.

CAUTION:

Risk of damaging the brake system due to improper handling of brake fluid.

Oils containing minerals damage plugs and boots on brake systems.

- Prevent mixing mineral liquids such as oil, gasoline and cleaning solution with brake fluid.

CAUTION:

Brake fluid is hygroscopic, meaning that it absorbs moisture from the surrounding air.

If the water content of the brake fluid is too high, it can lead to brake system failure and also promotes corrosion inside of the brake system.

- Store brake fluid in tightly-sealed containers.

Brake Fluid, Extracting

-- Remove the cap -1- from the brake fluid reservoir.

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-- Insert the suction hose from the Brake Charger/Bleeder Unit through the screen -1- in the brake fluid reservoir to extract as much brake fluid -2- as possible.

Fig 4: Suction Hose From The Brake Charger/Bleeder Unit

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NOTE:

Do not remove the screen inside the brake fluid reservoir.

After extracting, observe that no further brake fluid runs into the reservoir (the brake fluid level in the reservoir must align with the lower edge of the screen).

Attach the brake charger/bleeder unit:

-- Attach the adapter -1- to the brake fluid reservoir.

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-- Attach the hose from the Brake Filling and Bleeding Equipment to the adapter -1-.

-- Set the correct pressure on the Brake Charger/Bleeder Unit (refer to the Owner's Manual) and switch on the Brake Charger/Bleeder Unit.

NOTE:

The bleed hose must fit tightly over the bleed screw to prevent air from getting into the brake system.

The brake fluid level in the reservoir must be high enough so that air cannot get into the brake system.

For RHD vehicles, begin with the right front.

By using the Brake Bleeding Tool Set - Insert Tool: VAS 6564/9 , the removal of the rear wheels is no longer necessary.

Front Axle

-- Remove the cap -1- from the bleed screw on the left front brake caliper.

Fig 5: Identifying Bleeder Screw Cap

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-- Connect the collector bottle bleed hose -1- to the left front bleeder valve.

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-- Open the breather valve and let the corresponding quantity of brake fluid drain out. Refer to Sequence and Brake Fluid Capacity Table .

-- Close the bleeder screw. Tightening specification. Refer to OVERVIEW - FRONT BRAKE CALIPER .

-- Reattach the brake caliper bleeder screw cap.

-- Repeat the steps on the front right side.

Rear Axle

-- Remove the cap -1- on the left rear brake caliper breather valve.

Fig 6: Identifying Bleeder Screw Cap (Rear)

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-- Use the Brake Bleeding Tool Set - Insert Tool: VAS 6564/9 for the rear axle.

-- Guide the bleeder hose -1- from the Brake Bleeding Tool Set: VAS 6564 from the inside of the rim through the socket -3- and connect to the bleed screw.

Fig 7: Bleeding Rear Brakes

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-- Open the breather valve and let the corresponding quantity of brake fluid drain out. Refer to Sequence and Brake Fluid Capacity Table .

-- Close the bleeder valve. For the tightening specification, refer to OVERVIEW - REAR BRAKE CALIPER .

-- Install the cap on the left rear brake caliper bleed valve.

-- Repeat the same procedure on the right rear side of the vehicle.

Clutch Slave Cylinder, Bleeding

NOTE:

Only on vehicles with a manual transmission.

-- When the bleeder valve -arrow- is not accessible, then remove the entire air filter housing.

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-- Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING (1.5L) .

-- Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING (2.0L) .

-- Remove the dust cap from the breather valve -arrow-.

-- Connect the bleed hose and connect the pressure hose with the collector bottle.

Use the Bleed Hose (670 mm long): V.A.G 1238/B3 if necessary to bleed.

-- Open the breather valve.

-- Allow approximately 100 ml brake fluid to escape.

-- Close the bleeder valve.

-- Push the clutch pedal quickly from stop to stop 10 to 15 times.

-- Open the breather valve.

-- Allow another 50 ml brake fluid to escape.

-- Close the breather valve and install the dust cap.

Tightening Specification	Nm
Breather valve	4.5

-- After completing the bleeding procedure press the clutch pedal several times.

-- Switch off the Brake Charger/Bleeder Unit.

-- Install the air filter housing in reverse order of removal.

-- Remove the filler hose from the adapter.

-- Remove the adapter from the brake fluid reservoir.

-- Check the brake fluid level and correct if necessary. The brake fluid level must be between positions -1- and -2-.

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-- Screw on the brake fluid reservoir cap -1-.

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-- Perform a function test during the test drive.