Brake And Clutch System, Changing Brake Fluid: Notes

Special tools and workshop equipment required

Mini Torque Wrench:VAS6854

Fig 1: Identifying Mini Torque Wrench VAS 6854
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Brake Filling and Bleeding Equipment:VAS6860

Fig 2: Brake Filling and Bleeding Equipment :VAS6860
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Brake Bleeding Tool Set - Insert Tool:VAS6564/9

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Brake Bleeding Tool Set:VAS6564

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

Brake fluid must never come into contact with fluids containing mineral oils (oil, gas, cleaning solutions). Oils containing minerals damage seals and rubber grommets on brake systems.
Brake fluid is poisonous. Do not let brake fluid come in contact with the paint due to is corrosive effects.
Brake fluid is hygroscopic, which means that it absorbs moisture from the air. Always store brake fluid in air-tight containers.
Wash off any spilled brake fluid with plenty of water.
Do not use extracted (used) brake fluid again!
Follow all disposal regulations.

Extract the Brake Fluid

-- 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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-- Connect the hose on the Brake Charger/Bleeder Unit to the adapter -1-.

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

By using the :VAS6564/9 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 breather valve.

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

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

-- Reattach the brake caliper bleeder screw cap.

-- Repeat the steps for the front right.

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 :VAS6564/9 for the rear axle.

-- Guide the bleed hose -1- from the :VAS6564 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 Sequence and Brake Fluid Capacity Table .

-- Closer the breather valve: torque. 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.

Bleeding the Clutch Slave Cylinder

NOTE:

Only on vehicles with a manual transmission.

-- When the breather valve -arrow- is not accessible, then remove the complete air filter housing.

-- Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING .

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

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

Use the :VAG1238/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 fill if necessary. It must be between -1- and -2-.

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-- Install the brake fluid reservoir cover -1-.

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-- Perform a function test during the test drive.