This Volkswagen Golf and Jetta Braking System Manual contains the Brake calipers – removal, overhaul and refitting Brake discs – examination, removal and refitting Brake pads- inspection and renewal Brake pressure regulator – testing, removal and refitting Footbrake pedal – removal and refitting General information and precautions Handbrake cables – removal, refitting and adjustment Handbrake lever – removal and refitting Hydraulic pipes and hoses – renewal Hydraulic system – bleeding Master cylinder – removal and refitting Rear brake cylinder – removal, overhaul and refitting Rear brake drum – examination and renovation Rear brake shoes – inspection and renewal Rear hub bearings – renewal Vacuum servo unit – removal and refitting Vacuum servo unit – testing Degrees of difficulty Easy, suitable for novice with little experience

1 Fairly easy, suitable for beginner with some experience 2 Fairly difficult, suitable for competent DIY mechanic 3 Difficult, suitable for experienced DIY mechanic 4 Very difficult, suitable for expert DIY or professional 5 Specifications Brake system Type Hydraulic, dual circuit, split diagonally, pressure regulator on some models. Disc front brakes. Drum or disc rear brakes. Cable-operated handbrake on rear wheels. Front brakes Disc thickness: New: 1.05 and 1.3 litre 1.6 and 1.8 litre 1.8 litre with ventilated discs Minimum: 1.05 and 1.3 litre 1.6 and 1.8 litre 1.8 litre with ventilated discs Pad thickness: New – excluding backplate: 1.05 and 1.3 litre 1.6 and 1.8 litre 1.8 litre with ventilated discs Minimum – including backplate: All models 10.0 mm 12.0 mm 20.0 mm 8.0 mm 10.0 mm 18.0 mm 12.0 mm 14.0 mm 10.0 mm 7.0 mm Rear drum brakes Drum internal diameter: New Maximum Drum maximum run-out: Radial – at friction surface Lateral – wheel contact surface Lining thickness: Minimum – including shoe Minimum – excluding shoe 180.0 mm 181.0 mm 0.05 mm 0.2 mm 5.0 mm 2.5 mm 1081 VW Golf & Jetta Braking system Rear disc brakes Disc thickness: New Minimum Disc maximum run-out Pad thickness: New – including backplate Minimum – including backplate 10.0 mm 8.0 mm 0.06 mm 12.0 mm 7.0 mm Master cylinder Diameter 20.65 mm Wheel cylinder Diameter 14.29 mm Servo unit Diameter: Manual gearbox Automatic transmission 178.0 mm 228.0 mm Nm 25 25 20 20 10 60 35 65 60 110 Ibf ft 19 19 15 15 7 44 26 48 44 81 When servicing any part of the system, work carefully and methodically. Observe scrupulous cleanliness when overhauling any part of the system. Always renew components (in axle sets, where applicable) if in doubt about their condition and use only genuine VW replacement parts, or at least those of known good quality. Torque wrench settings Caliper upper securing bolt Caliper lower securing bolt Master cylinder securing nuts Servo unit securing nuts Splash guard to strut Backplate to rear axle Rear disc brake guide pin (self-locking) Rear disc brake carrier bolts Rear disc brake cover plate-to-axle bolts Roadwheel bolt General information and precautions General information The braking system is of hydraulic, dual circuit type with discs at the front and drum or discs at the rear. The hydraulic circuit is split diagonally so that with the failure of one circuit, one front and one rear brake remain operative. A load-sensitive pressure regulator is incorporated in the rear hydraulic circuits on some models to prevent the rear wheels locking in advance of the front wheels during heavy application of the brakes. The regulator proportions the hydraulic pressure between the front and rear brakes according to the load being carried and is located on the under-body, in front of the left-hand rear wheel. A vacuum servo unit is located between the brake pedal and master cylinder. It provides assistance to the driver when the brake pedal is depressed. The unit operates by vacuum from the inlet manifold and comprises a diaphragm and non-return valve. With the brake pedal released, vacuum is channelled to both sides of the diaphragm. With the pedal depressed, one side is opened to atmosphere. The resultant unequal pressures are harnessed to assist in depressing the master cylinder pistons. The handbrake operates on the rear wheels only, its lever incorporating a switch which illuminates a warning light on the instrument panel when the handbrake is applied. The same warning light is wired into the low hydraulic fluid switch circuit.

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