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Change brake fluid
Special tools and workshop equipment required
t  Brake filling and bleeding device, e. g. -VAS 5234-
t  Tool set for brake bleeding -VAS 6564-
Use only new genuine brake fluid N.052.766.Z0 which conforms to the USA standard FMVSS 571.116, DOT 4 and VW standard 501 14. Brake fluid capacity →Brake systems; Rep. gr.00.
  WARNING
t  Brake fluid must never come into contact with fluids containing mineral oils (oil, petrol, cleaning agent). Mineral oils damage the gaskets and boots of the brake system.
t  Brake fluid is poisonous. Also due to its corrosive effect brake fluid must not come into contact with paintwork.
t  Brake fluid is hygroscopic, i.e. it absorbs moisture from the surrounding air. Therefore it should always be stored in airtight containers.
t  Wash any parts stained with brake fluid with large volumes of water.
t  Observe the disposal instructions!
  Note
t  The described procedure for changing the brake fluid refers to the use of the Brake filling and bleeding device-VAS 5234-.
t  When using a different type of brake filling and bleeding device, settings and usage may change. However, this has no effect on the technological procedure of a brake fluid change.
t  Precise information must always be obtained from the → Operating instruction of the brake filling and bleeding device.
Extract brake fluid from the brake fluid reservoir.
    
–  Switch on the extraction function of the brake filling and bleeding device, e.g. -VAS 5234-.
1 -  Catch pan
2 -  Connecting hose
3 -  Pneumatic support
4 -  Extraction hose with end part
5 -  Filling hose with quick coupling
6 -  Unit connecting point
7 -  Connecting hose
–  Connect brake filling and bleeding device, e. g. -VAS 5234-, to the compressed air distribution.
   S02-0653
–  Position cock -1- on -B-.
–  Set switch -2- upwards on -vacuum-.
   S02-0654
–  Unscrew plug -2- from the brake fluid reservoir.
–  Switch on the compressed air distribution, herewith the brake filling and bleeding device, e.g. -VAS 5234-, is operative. -VAS 5234-.
   S02-0658
–  Use an extraction hose -1- with end part to extract as much brake fluid as possible from the brake fluid reservoir.
  WARNING
Drained (used) brake fluid must never be used again.
   S02-0660
–  Set back switch -2- from -vacuum- down.
–  Switch off the compressed air distribution, herewith the brake filling and bleeding device, e.g. -VAS 5234-, is no longer operative. -VAS 5234-.
   S02-0654
–  Screw the plug -2- onto the brake fluid reservoir.
Change brake fluid in slave cylinder - vehicles with manual gearbox
–  Remove engine cover.
–  Remove air filter →Relevant Engine; Rep. gr.23 or →Relevant Engine; Rep. gr.24.
   S02-0658
–  Switch on the filling function of the brake filling and bleeding device, e.g. -VAS 5234-, as follows.
–  Detach connecting hoses -2- and -7- from catch pan -1-.
–  Detach the filling hose with quick coupling -5- from the unit connecting point -6-.
   S02-0653
–  Unscrew cap -1- from the brake fluid reservoir
   S02-0658
–  Screw the thread plug -1- of the brake filling and bleeding device, e.g. -VAS 5234-, onto the brake fluid reservoir.
1 -  Thread plug
2 -  Filling hose with quick coupling
3 -  Compressed air distribution
–  Switch on the compressed air distribution, herewith the brake filling and bleeding device, e.g. -VAS 5234-, is operative. -VAS 5234-.
   S02-0659
–  Check the filling pressure of the brake fluid on the pressure gauge -1-.
   Filling pressure of brake fluid = 0.2 MPa.
–  Set the filling pressure e.g. by turning the regulating valve -2-.
   S02-0657
–  Provide a catch pan for used brake fluid.
  Note
t  Slacken the vent valve using the set of tools for brake bleeding -VAS 6564- and tighten. While doing so, pull the bleeder hose through the socket insert with a corresponding hollow adapter piece from this set.
t  Fit a torque wrench on the socket insert with a corresponding hollow adapter piece for tightening the vent valve.
   A02-0334
–  Fit the hose of the extraction device -A- onto the vent valve -arrow- of the slave cylinder.
–  Open vent valve and allow approx. 0.1 litres of brake fluid to flow out.
–  Tighten the vent valve with corresponding tightening torque →Relevant gearbox; Rep. gr.30.
–  Detach bleeder hose of catch pan.
–  Install air filter →Relevant Engine; Rep. gr.23 or →Relevant Engine; Rep. gr.24.
–  Install the engine cover.
–  After completing the bleeding procedure press the clutch pedal repeatedly.
Change the brake fluid in the brake system
  Note
t  Carry out the brake fluid change in the brake system, without removing the wheels from the vehicle.
t  In view of the different versions of the wheels and the brake calipers, tightening the bleeder valves using the set of tools for brake bleeding -VAS 6564- (with the torque wrench inserted) cannot always be performed due to lack of space.
t  In this case, the corresponding wheels must be removed from the vehicle. Do not exchange the wheels and mark their position opposite the brake disc/drum.
t  Tightening torque of the wheel screws = 120 Nm.
–  Raise vehicle.
–  Hook in the catch pan on the vehicle.
–  Remove the rubber cap from the bleeder valve on the rear right wheel.
   N30-0205
–  Fit bleeder hose -1- of catch pan onto the bleeder valve of the rear right wheel.
  Note
t  Slacken the bleeder valves using the set of tools for brake bleeding -VAS 6564- and tighten. While doing so, pull the bleeder hose through the socket insert with a corresponding hollow adapter piece from this set.
t  Fit a torque wrench on the socket insert with a corresponding hollow adapter piece for tightening the vent valve.
–  Loosen the bleeder valve and allow approx. 0.3 litres of brake fluid to flow out.
–  Tighten bleeder valve to corresponding tightening torque →Brake systems; Rep. gr.47.
–  Detach hose of catch pan.
–  Fit the rubber cap onto the bleeder valve and remove the catch pan from the vehicle.
–  Repeat this procedure for all wheel-brake cylinders/brake calipers.
   S02-0445
Sequence: slave cylinder, brake caliper Quantity of brake fluid which must flow out:
Slave cylinder 0,1 litre
Rear right 0,3 litre
Rear left 0,3 litre
Front right 0,2 litre
Front left 0,2 litre

Total amount of brake fluid discharged: approx. 1.15 ltre, incl. the amount drained from the brake fluid reservoir.
–  Switch off and disconnect the brake filling and bleeding device.
–  Check brake fluid level → Chapter and screw the cap onto the brake fluid reservoir.
–  Activate the brake pedal repeatedly.
–  Check that the pedal „does not fall through“ when it is pressed down repeatedly with force.
–  Check the brake pedal-idle travel on the brake pedal. Idle travel: max. 1/3 of pedal travel.
–  Perform a test drive.
During a test drive, at least one ABS adjustment must be carried out on vehicles with ABS!
   


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