Volkswagen Workshop Manuals

8/12/2019 Volkswagen Workshop Manuals

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Volkswagen Workshop Manuals

Polo Mk4

Running gearBrake systemsTechnical data>>Technical data


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+ront 'heel brakes

PR number +ront 'heel brake"- . "A . /0 +S )) 1 234

"5 . /+ . /5 . "6 . /7 . "R . /R +S ))) 1 834"0 . /( C 98:)) 1 934

Rear 'heel disc brakePR number Rear 'heel brake

;; C 2;T C 2;S C 28

Rear 'heel drum brake

PR number Rear 'heel brake

;B TB = ? 8 CR @ mm

;- TB = ? 8 CR mm

Brake technical data

Brake cylinder in mm = , 8Brake cylinder in mm , 9 D 0oteSer#o brake in inches ,9

Brake systems > Technical data > Technical data > Brake technical data > Front wheel brake FS II
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&ront wheel brake &)II

pos.

/R n#mber 1'+ 0 1'A

(witho#t powersteering$

!rake c linder 3mm

14.56 witho#t A!)

)ervo brake 3 in 7,68899

1 !rake caliper &) II (1 ;$

% !rake pad,thickness

mm 1%

!rake disc 3mm

% 4

!rake disc,thickness

mm 17

8 !rake caliper,pl#nger

3mm

87


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Brake systems > Technical data > Technical data > Brake technical data > Front wheel brake FS III

&ront wheel brake &)III

pos

.

/R n#mber 1'< 0 1=& 0 1=< 0 1' 0 1=> 0

1'R 0 1=R

(with power steering$

!rake c linder 3mm

%5,?8


1 !rake caliper &) III (18;$


mm 18,1@

!rake disc 3mm

%6?


mm %%


3mm

68
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Polo Mk4

Brake systems > Technical data > Technical data > Brake technical data > Front wheel brake C54-FN

&ront wheel brake 68-&

pos.

/R n#mber 1' 0 1=B

(with powersteering$

!rake c linder 3mm

%5,?8


1 !rake caliper 68-& (16;$


mm 1 ,?8

!rake disc 3mm

%77


mm %6


3mm

68


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Brake systems > Technical data > Technical data > Brake technical data > !ear wheel di"c brake

Rear wheel discbrake

pos.

/R n#mber 1 01 *

!rake c linder 3mm

%5,?8


1 !rake disc 3mm

% %


mm 4


mm 11,8

!rake caliper,pl#nger

3mm

7

Brake systems > Technical data > Technical data > Brake technical data > !ear wheel dr#m brake witho#t $%S
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Rear wheel dr#m brake witho#tA!)

pos.

/R n#mber 1 ! 01 +

!rake c linder 3mm

%5,?814,56 1$


1 heel brakec linder

3mm

1@,8?14,56

% !rake shoe,thickness

mm 6

!rake shoe, width mm 7.7

!rake dr#m 3mm

%55

Cnl for vehicles with 1 D R#nning Technical data > Technical data > Brake technical data > !ear wheel dr#m brake with $%S


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Rear wheel dr#m brake withA!)

pos.

/R n#mber 1 ! 01 +

!rake c linder 3mm

%5,?8


1 heel brakec linder

3mm

1@,8?14,56

% !rake shoe,thickness

mm 6

!rake shoe, width mm 7,7

!rake dr#m 3mm

%55

Brake systems > $%S& $'!& (CS& E')& ES* > +eneral information on the antilock braking ","tem $%S.


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Brake systems > AB ! A"R! TC ! #"$! # P > %eneral information on the antilock braking system &AB ' > $%S /0 12

A!) +?5

*he A!) + ?5 s stem is available in the followingversions:

tA!)

tA!)0E")0A)R

*he A!) brake s stem is arranged diagonall . *he braking power amplification is carriedo#t pne#maticall thro#gh the vac##m servo brake.

ehicles with A!) + ?5 do not have a mechanical braking power reg#lator. A specialsoftware installed in the command #nit controls the distrib#tion of braking power to the rearaxle.

&a#lts in the A!) do not affect the brake s stem and servo brake and the normal brakes stem also operates witho#t A!). A difference in the braking behavio#r is to be expected.After the control lamp for A!) and the control lamp for the brake s stem light #p, the rear

wheels ma lock in advance d#ring braking.

A!)location:

1 -B dra#lic #nit and command#nit (8@ poles$.

% -)ervobrake
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*he command #nit -1- (8@poles$ and the h dra#lic #nit-%- form one single #nit.)eparation is onl possible

with components d#ldisassembled. It is forbiddento separate the h dra#lic p#mp

- - from the h dra#lic s stem#nit. In the two connectorterminals there are two largecontacts with 8.7 mm of widthfor each one.

Remove and install thecommand #nit and theh dra#lic #nit 2 hapter .

Polo Mk4

Brake systems > AB ! A"R! TC ! #"$! # P > %eneral information on the antilock braking system &AB ' > $%S %o"ch 53

A!) !osch6.@

A!) !osch 6.@ is available in the followingversions:

tA!)

tA!)0E")0A)R0E)/


&a#lts in the A!) do not affect the brake s stem and servo brake and the normal brake

s stem also operates witho#t A!). A difference in the braking behavio#r is to be expected.After the control lamp for A!) and the control lamp for the brake s stem light #p, the rear


In case of complaints, the h dra#lic #nit and the command #nit m#st be replacedtogether.


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A!)location:

1 -B dra#lic #nit and command

#nit

% -)ervobrake

*he command #nit -1-and the h dra#lic #nit-%- form one single#nit. )eparation is onlpossible withcomponents d#ldisassembled. *heh dra#lic p#mp -8-m#st not be separatedfrom the h dra#lics stem #nit (- -!rakepress#re sensor 1 - AB ! A"R! TC ! #"$! # P > %eneral information on the antilock braking system &AB ' > %o"ch 32 a" of 6ear7/odel 8225

!osch 7.5 as of Fear0+odel%556

*he A!) !osch 7.5 in this vehicle has the followingconfig#ration:

tA!)

t A!)0A)R

tA!)0E")0A)R0E)/


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&a#lts in the A!) do not affect the brake s stem and servo brake and the normal brakes stem also operates witho#t A!). A difference in the braking behavio#r is to be expected.After the control lamp for A!) and the control lamp for the brake s stem light #p, the rear


A!)location:

1 -)ervobrake

% -B dra#lic s stem #nit andcommand device

*he command device -1- and theh dra#lic s stem #nit -%- form one#nit. In case of damage, replaceboth the command device and theh dra#lic s stem together. It isforbidden to separate the h dra#licp#mp - - from the h dra#lics stem #nit.

!osch 7.5 A!) andA!)0A)R:

ommand device and h dra#lics stem #nit 2 hapter .


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!osch 7.5A!)0E")0A)R0E)/:

ommand device and h dra#lics stem #nit 2 hapter .

Polo Mk4

Brake systems > AB ! A"R! TC ! #"$! # P > Information on $%S ","tem repair

Information on A!) s stemrepairof the GAssisted fa#lt diagnosis;.

t *he components removed m#st be placed on a clean s#rface and
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covered over.

tIf the repair tasks are not carried o#t immediatel , caref#ll cover the open components orplace them in a proper location. (Hse the 1B5 ?47 11 A repair set lid$

tHse lint-freecloths.

tCnl remove the replacement parts from their packages immediatel beforeassembl .

tHse onl parts in originalpackaging.

t"o not work with compressed air nor move the vehicle with the s stemopen.

t+ake s#re that no brake fl#id comes into contact with theconnectors.

t "#ring painting, the command #nit ma be momentaril s#bmitted to a maxim#mtemperat#re of 46 , and for longer periods (approximatel % ho#rs$ with the maxim#m of76 .

Polo Mk4

Brake systems > AB ! A"R! TC ! #"$! # P > Connect the 'iagno"i"& /ea"#rement and Information S,"tem 9$S 525:$ 758 and "elect thef#nction"

onnect the "iagnosis, +eas#rement and Information ) stem - A) 6561A 06%-and selectthe f#nctions

)pecial tools and workshop eJ#ipmentreJ#ired

t"iagnosis, meas#rement and information s stem - A)6561-

t"iagnosis cable - A) 656101- or"iagnosis cable - A) 65610 -

AR I AB ! A"R! TC ! #"$! # P > #lectrical(electronic components and installing locations > $%S /0 12 $%S& $%S7E'S7$S!.

A!) + ?5 (A!),A!)0E")0A)R$

1 -B dra#lic A!) #nit- 66-

*he h dra#lic #nit comprises the followingcomponents:

JA!) h dra#lic p#mp- ?8-

Jalve block (incl#des intake and exha#st

valves$

Jit can be checked with the "iagnosis, +eas#rement and Information ) stem - A)6561A06%-

J*he A!) h dra#lic p#mp - ?8- and the valve block ma not beseparated

J remove and install
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2 hapter

% -A!) control #nit->158-

J it can be checked in the f#nction GAssisted *ro#bleshooting; with the "iagnosis,+eas#rement and Information ) stem - A) 6561A06%-

Jdo not disconnect the command #nit connector before the self-diagnosis

Jremove and install2 hapter

-!rake pedal switch-&8@-

JRemove and install2 hapter

8 - !rake pad wear control lamp- %-

JInstallation location: on the instr#mentpanel

nction:2 hapter

6 -A!) control light- 8@-

J Installation location: on the instr#mentpanel

nction:2 hapter

? -!rake s stem control light -

117-


nction:2 hapter

@ -A)R control lamp- 7?-


nction:2 hapter

7 -"iagnosisconnector

J Installation location: 'ining on the driver9s side feet


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area

4 -e for

A)R

JCnl vehicles withA!)0E")0A)R


15 -Right rear wheel speed sensor -


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"iagnosisconnector

Polo Mk4

Brake systems > AB ! A"R! TC ! #"$! # P > #lectrical(electronic components and installing locations > $%S %o"ch 53$%S7E'S7$S!7ES*.

A!) !osch 6.@(A!)0E")0A)R0E)/$


20/126



JA!) refl#x p#mp- 4-

J it can be checked in the f#nction GAssisted *ro#bleshooting; with the "iagnosis,+eas#rement and Information ) stem - A) 6561A 06%- 2 hapter

Jalve block (incl#des intake and exha#st

valves$

J*he A!) refl#x p#mp - 4- and the valve block m#st not be separated fromeach other

Jremove and install

2 hapter


J it can be checked in the f#nction GAssisted *ro#bleshooting; with the "iagnosis,


21/126

+eas#rement and Information ) stem - A) 6561A 06%- 2 hapter



-!rake press#re sensor 1-


22/126

2 hapter


JInstallation location: 'ining on the driver9s side feetarea

15 -)teering angle sensor-


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2 hapter

16 -heel h#b0roller bearing

assembl

Jthe A!) sensor ring is assembled in the wheel rollerbearing

1? -heel h#b0roller bearing

assembl


"iagnosisconnector

Polo Mk4

Brake systems > AB ! A"R! TC ! #"$! # P > #lectrical(electronic components and installing locations > $%S %o"ch 32 $%S& $%S7$S!.

A!) !osch 7.5 (A!),A!)0A)R$


24/126


*he h dra#lic #nit s stem comprises the followingcomponents:


J it can be checked in the f#nction GAssisted *ro#bleshooting; with the "iagnosis,+eas#rement and Information ) stem - A) 6561A 06%-

Jvalve block (incl#des intake and exha#stvalves$

J*he A!) refl#x p#mp - 4- and the valves m#st not beseparated.

Jremove and install

2 hapter




25/126

+eas#rement and Information ) stem - A) 6561A 06%-

J"o not disconnect the command #nit connector before the self-diagnosis


-!rake light switch -&- and !rake pedal switch-&8@-


8 -!rake pad wear control lamp- %-

Jinstallation location on instr#mentpanel

nction:2 hapter


Jinstalling location: on the instr#mentpanel

nction:2 hapter

? - !rake s stem control light -117-


nction:2 hapter

@ -A)R control lamp- 7?-

Jin vehicles with A!)0A)Ronl


nction:2 hapter


Jinstalling location: on the foot compartment cover, on the driver9sside

4 - )witch for A)R


26/126

-E1 %-

Jin vehicles with A!)0A)Ronl


15 -Right rear wheel speed sensor -


27/126




J it can be checked in the f#nction GAssisted *ro#bleshooting; with the "iagnosis,+eas#rement and Information ) stem - A) 6561A 06%-

Jvalve block (incl#des intake and exha#stvalves$

J*he A!) refl#x p#mp - 4- and the valves m#st not beseparated

Jremove and install

2 hapter




28/126




-!rake light switch -&- and !rake pedal switch-&8@-


8 -!rake pad wear control lamp- %-


nction:2 hapter



nction:2 hapter

? - !rake s stem control light -117-


nction:2 hapter

@ -A)R and E)/ control light- 166 -


nction:2 hapter


JInstallation location: 'ining on the driver9s side feetarea

4 -)teering angle sensor-


29/126


JInstallation location: on the steering col#mn, between the steering wheel and the steeringcol#mn switch

JCbserve the assemblg#idelines

2 hapter

15 -'ateral acceleration sensor -


30/126

assembl


Polo Mk4

Brake systems > AB ! A"R! TC ! #"$! # P > Fa#lt indication via control lamp"

&a#lt indication via controllamps

ontrollamps

pos.

omenclat#re

1 !rake pad wear control lamp- %-

% A!) control light - 8@-

!rake s stem control light- 117-

8 A)R control lamp - 7?-

A)R and E)/ control light- 166-

!rake pad wear control lamp- %-
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t

If the ontrol light for brake pad wear - %--1- does not go offafter t#rning the ignition on andafter the inspection is over, or ifit lights #p while the vehicle ismoving, the fa#lt ma have thefollowing ca#ses:

-a- the brake pads ma be worn.

heck the front and rear brakepads.

-b- an activation fail#re in theontrol light for brake pad wear

- %-. 2 Electrical diagrams,diagnosis of electrical fa#lts andinstallation locations .

A!) control light -8@-

t

If the A!) control light - 8@--%-does not t#rn off after switchingthe ignition on and after finishingthe check, the fa#lt ma res#ltfrom the following probableca#ses:

-a- the voltage s#ppl is below 15olt.

-b- there is a fa#lt in theA!).

In the case of a fa#lt in the A!)-b-, the antilock braking s stem ist#rned off, while the conventionalbrake s stem remains f#lloperational.

-c- there was a temporar fa#lt inthe speed sensor from the the lasttime the vehicle was started.

In case of speed sensor -c-, theA!) control light - 8@- will bea#tomaticall t#rned off afterstarting the vehicle and at speedsover %5 km0h.

-d- there is an interr#ption in theconnection between theinstr#ment panel and the A!)control #nit ->158-. 2 Electricaldiagrams, diagnosis of electrical


32/126

fa#lts and installation locations .

A!) control light - 8@- and !rakes stem control light - 117-

t

If the A!) control light - 8@--%-goes off, b#t the control lamp!rake s stem control light- 117-- - remains on, the fa#ltma have the following ca#ses:

-a- the handbrake ison.

-b- the brake fl#id level is toolow.

-c- there is a fa#lt in the activationof the !rake s stem control light- 117- 2 Electrical diagrams,diagnosis of electrical fa#lts andinstallation locations .

t

If the A!) control light - 8@--%-and !rake s stem control light- 117-- - are t#rned on, thismeans that the A!) and E!(electronic braking powerdistrib#tion$ have failed.

AR I AB ! A"R! TC ! #"$! # P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > $%S /0 12

A!) +?5

*he brake c linder and the servo brake ma be independentlreplaced.

AR I AB ! A"R! TC ! #"$! # P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB M, -. > )oo"en thecommand #nit from the h,dra#lic #nit

'oosen the command #nit from the h dra#lic#nit

K /osition the h dra#lic #nit and the command #nit down and on a clean and flat
http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/abs_mk_60/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/abs_mk_60/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/abs_mk_60/


47/126

s#rface.

K'oosen the internal *orx E6screws -arrows- on the h dra#lic#nit.

AR I AB ! A"R! TC ! #"$! # P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB M, -. > In"tall a newcommand device

Install a new commanddevice

AR I AB ! A"R! TC ! #"$! # P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > $%S %o"ch 53

A!) !osch

6.@


AR I 158-


% -B dra#lic A!) #nit- 66-

J In the h dra#lic #nit the A!) h dra#lic p#mp - ?8- and the intake and exha#st valves arechecked thro#gh self-diagnosis

J*he A!) h dra#lic p#mp - ?8- and the valve block ma not beseparated

Jhen replacing the h dra#lic #nit, seal the old part with the pl#gs from the repair set

n#mber E* 1B5 ?47 11 A


-Externalscrew

Jm

8 -!rake press#re sensor 1

-


50/126

connection

JB dra#lic #nit for left front brakecaliper

JIdentification in the h dra#lic #nit- '-

? -!rake pipeconnection

JB dra#lic #nit for right front brakecaliper

JIdentification in the h dra#lic #nit- R-

@ -!rake pipeconnection

J !rake c linder0floating pl#nger loop for the h dra#lic#nit

JIdentification in the h dra#lic #nit-B=%-

7 -!rake pipeconnection

J!rake c linder0press#re pl#nger loop to the h dra#lic#nit

J Identification in the h dra#lic #nit-B=1-


Jfor the left rear brakecaliper

JIdentification in the h dra#lic #nit-B'-


Jfor the right rear brakecaliper

JIdentification in the h dra#lic #nit-BR-

11 -)ervobrake

JCn gasoline engines, the vac##m reJ#ired is removed from the intakemanifold.

J Cn diesel engines, a vac##m p#mp is installed to create


51/126

vac##m.

Jheck the

operation

J /ress the brake pedal several times #ntil the end with the engine stopped (*his eliminatesan remaining vac##m inside the device$.

Jow, keep the brake pedal pressed in the braking position with medi#m force and start the

engine. hen the servo brake is working properl , this can be felt with a foot on the brakepedal (the amplification is active$.

JIn case of fa#lts, replacecompletel

Jheck valve (in the vac##m hose$

2 hapter

Jseparate from the brake pedal2 hapter


1% -)ealing

Jto servobrake

1 -)elf-locking hex headn#t

Jreplace

J%7

m

18 -)ealingring

Jreplac

e


Jreplace

J%5

m

1? -!rakec linder

Jcannot be repaired. here fa#lts occ#r, replacecompletel .


52/126


1@ -Retaining pin for the brake fl#idreservoir

Jinsert thro#gh the brakec linder

17 - )ealingpl#g

Jmoisten with brake fl#id and press in the brakec linder

14 -)ealingpl#g

Jonnection for vac##m

hose

%5 -!rake fl#idreservoir

%1 -/l#g

%% -)elf-locking hex headn#t

Jreplace

J%5

m

% -)#pport

%8 -)t#d

J)t#d welded to the

bod

%6 -)crews

J7

m

%? -)#pport

%@ -)crews

J7

m


53/126

%7 -)elf-locking hex headn#t

Jreplace

J%5

m

%4 - )t#d

J)t#d welded to thebod

Polo Mk4

Brake systems > AB ! A"R! TC ! #"$! # P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch /01 > Connectthe brake pipe" and the brake c,linder pipe" to the h,dra#lic #nit

onnect the brake pipes and thebrake c linder pipes to theh dra#lic #nit

- Identification in the h dra#lic
http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/abs_bosch_5.7/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/abs_bosch_5.7/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/abs_bosch_5.7/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/abs_bosch_5.7/


54/126

#nit -BR-

8 -B dra#lic #nit to left rear brakecaliper

-Identification in the h dra#lic#nit -B'-

Polo Mk4

Brake systems > AB ! A"R! TC ! #"$! # P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch /01 > Command#nit for h,dra#lic #nit - remove and in"tall

ommand #nit for h dra#lic #nit - remove andinstall


tD*orJ#e wrench - 6 to 65 m(enc. 10%D$D - A< 1 1-

t!rake pedal pressing device- A< 17?40%-


55/126

/l#g repair set 1B5 ?4711 A

After disconnecting the commanddevice from the h dra#lic #nit,alwa s place the valve t#betransport protection in theh dra#lic #nit

B dra#lic #nits witho#t thetransport protection are notcovered b warrant .

1 -alve t#be transport

protection

% -/l#gs +15

-/l#gs +1%

Remove

Installationlocation:

*he command #nit is screwed tothe h dra#lic s stem #nit and isfo#nd in the right side of the

engine compartment.

AR I AB ! A"R! TC ! #"$! # P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch /01 > Command#nit for h,dra#lic #nit - remove and in"tall

Polo Mk4

Brake systems > AB ! A"R! TC ! #"$! # P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch /01 > !emovethe h,dra#lic #nit command device

Remove the h dra#lic #nit command

deviceh dra#lic #nit and replace onl the command device.

t If the h dra#lic #nit is damaged, replace it along with the
http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/abs_bosch_5.7/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/abs_bosch_5.7/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/abs_bosch_5.7/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/abs_bosch_5.7/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/abs_bosch_5.7/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/abs_bosch_5.7/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/abs_bosch_5.7/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/abs_bosch_5.7/


60/126

command #nit

A!)0E")0A)R0E)/!osch 6.@

1 -ommand

device

% -B dra#lic#nit

-!rake press#resensor

8 -Refl#xp#mp

K Remove the external *orx E6screws -1 to ?- from theh dra#lic #nit.

*he *orx screws m#st not bere#sed.

AR I AB ! A"R! TC ! #"$! # P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch /01 > !emovethe h,dra#lic #nit command device

Polo Mk4

Brake systems > AB ! A"R! TC ! #"$! # P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch /01 > In"tall thecommand device to the h,dra#lic #nit

Install the command device to the h dra#lic#nit

hile installing the commanddevice -a- on the h dra#lic #nit -b-,ens#re that the valve t#bes -1- arenot bent with the electromagneticcoils -%-.

K Install the command device tothe h dra#lic #nit.

K

/ress the command device onthe h dra#lic s stem seatings#rface #ntil it fits completel

with the h dra#lic #nit rib andremains in this position.

KAlternatel tighten the centralscrews -1- and -%-, #ntil the

command device is fastened tothe h dra#lic #nit.


62/126

Hse the new *orx screws provided with the set.

KInstall screws - - to -?- andtighten the screws #ntil thecommand device is f#ll seated.

K*hen, alternatel tighten thecrews.

K*ighten the screws in theseJ#ence from -1- to -?- to

m.

*he h dra#lic #nit threads #sed tofasten the command device m#stnot be damaged. If the thread isdamaged (tro#ble in tightening thescrews man#all or screws not

tightened to the specified torJ#e$,replace the h dra#lic s stem #nit.

KIdentif with a p#nch, in thetraced area -arrow-, eachassembl of the h dra#lic #nit

with a command device.

ote

*he h dra#lic #nit s#pports onl 6assemblies in the command #nit.After 6 assemblies in thecommand #nit, it m#st bereplaced.

Brake systems > AB ! A"R! TC ! #"$! # P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch /01 > In"tall thecommand device to the h,dra#lic #nit

Polo Mk4

Brake systems > AB ! A"R! TC ! #"$! # P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch /01 > %rakepre""#re "en"or : +82:

!rake press#re sensor 1-


63/126

t c linders, inLection engine

2 Anchor

t8 c linders, inLection engine2 Anchor

t-c linder diesel engine

2 Anchor

t 8-c linder diesel engine with inLector p#mp #nit2 Anchor

t8 c linders, diesel engine with distrib#tion inLector p#mp2 Anchor

ontin#ation for allvehicles:

K "isconnect the connector - - ofbraking press#re sensor -%-.

K/#t an adeJ#ate n#mber of lint-free cloths #nder the command#nit and the h dra#lic #nit.

K "isconnect the brake pipes -1-from the h dra#lic #nit.

Klose the brake pipes and

threaded holes with pl#gs fromthe repair set n#mber

1B5 ?47 11 A.

KRemove the braking press#resensor.

Install

KInstallation is performed in thereverse seJ#ence of theremoval.

*ightening torJ#e:

!raking press#resensor

%5m

K!leed the brake s stem2 hapter

Brake systems > AB ! A"R! TC ! #"$! # P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch /01 > %rakepre""#re "en"or : +82:

Polo Mk4


64/126

Brake systems > AB ! A"R! TC ! #"$! # P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > $%S %o"ch 32

A!) !osch7.5


AR I 158-

Jremove and install the A!) h dra#lic #nit - 66- with theA!) control #nit ->158 - 2 hapter .

% - B dra#lic A!) #nit- 66-

J*heA!) refl#x p#mp - 4- and the co#pled valves m#st not beseparated.
http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/


65/126

Jhen replacing the h dra#lic #nit, seal the old part with the pl#gs from the repair set

n#mber E* 1B5 ?47 11 A

Jremove and install the A!) h dra#lic #nit - 66- with theA!) control #nit ->158 - 2 hapter .

-!rake pipeconnection

J B dra#lic #nit for right front brakecaliper

JIdentification in the h dra#lic #nit- R-


Jfor the left rear brakecaliper

JIdentification in the h dra#lic #nit-B'-


Jfor the right rear brakecaliper

JIdentification in the h dra#lic #nit-BR-

? -!rake pipeconnection

JB dra#lic #nit for left front brakecaliper

JIdentification in the h dra#lic #nit- '-

@ -!rake c linder

connection

J!rake c linder0floating pl#nger loop for the h dra#lic#nit

JIdentification in the h dra#lic #nit-B=1-

7 -!rake c linderconnection

J!rake c linder0floating pl#nger loop for the h dra#lic#nit

JIdentification in the h dra#lic #nit-B=%--


66/126

4 -)ealing

Jto servobrake

15 -)ervobrake

J Cn gasoline engines, the vac##m reJ#ired is removed from the intakemanifold.

JCn diesel engines, a vac##m p#mp is installed to createvac##m

JCperationchecking:

K/ress the brake pedal several times #ntil the end with the engine stopped (*his eliminatesan remaining vac##m inside the device$.

Kow, keep the brake pedal pressed in the braking position with medi#m force and start the

engine. hen the servo brake is working correctl , it can be felt with a foot on the brakepedal (the amplification is active$.

JIn case of fa#lts, replacecompletel

Jheck valve (in the flexible vac##m t#be$

2 hapter

Jseparate from the brake pedal 2 hapter .

Jdisassemble and assemble2 hapter


Jreplace

J %7m

1% -)ealingring

Jreplace


J replace

J %5


67/126

m

18 -!rakec linder

Jcannot be repaired. here fa#lts occ#r, replacecompletel .


16 -Retaining pin for the brake fl#idreservoir

Jinsert thro#gh the brakec linder

1? -)ealingpl#g

J moisten with brake fl#id and press in the brakec linder

1@ -)ealingpl#g

Jconnection to flexible vac##mt#be

17 -!rake fl#idreservoir

14 - /l#g

%5 -)crews

J7

m

%1 -)elf-locking hex headn#t

Jreplace

J%5

m

%% -)#pport

% -)t#d


%8 - )elf-locking hex head


68/126

n#t

Jreplace

J%5

m

%6 -)t#d


%? -)#pport

Brake systems > AB ! A"R! TC ! #"$! # P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > $%S %o"ch 3

Polo Mk4

Brake systems > AB ! A"R! TC ! #"$! # P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch 20. > Connectthe brake pipe" and the brake c,linder pipe" to the h,dra#lic #nit

onnect the brake pipes and the brake c linder pipes to theh dra#lic #nit

onnect the brake pipes and thebrake c linder pipes to theh dra#lic #nit:

A -B dra#lic #nit to the brakec linder press#re pl#nger loop

! -B dra#lic #nit to the brakec linder floating press#repl#nger loop

1 -B dra#lic #nit for left frontbrake caliper

-B dra#lic #nit to left rear brakecaliper

8 -B dra#lic #nit to right rearbrake caliper
http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/abs_bosch_8.0/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/abs_bosch_8.0/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/abs_bosch_8.0/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/abs_bosch_8.0/


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Cn the h dra#lic s stem#nit:

A -B dra#lic #nit to the brakec linder press#re pl#nger loop

-Identification in the h dra#lic#nit -B=1-

! -B dra#lic #nit to the brakec linder floating press#repl#nger loop

-Identification in the h dra#lic#nit -B=%-

1 -B dra#lic #nit for right frontbrake caliper

-Identification in the h dra#lic

#nit - R-

% -B dra#lic #nit to left rear brakecaliper

-Identification in the h dra#lic#nit -B'-

-B dra#lic #nit to right rearbrake caliper

-Identification in the h dra#lic#nit -BR-

8 -B dra#lic #nit for left frontbrake caliper

-Identification in the h dra#lic#nit - '-

Brake systems > AB ! A"R! TC ! #"$! # P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch 20. > Connectthe brake pipe" and the brake c,linder pipe" to the h,dra#lic #nit

Polo Mk4

Brake systems > AB ! A"R! TC ! #"$! # P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch 20. > Command#nit for h,dra#lic #nit - remove and in"tall

ommand #nit for h dra#lic #nit - remove andinstall



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tD*orJ#e wrench - 6 to 65 m(enc. 10%D$D - A< 1 1-

t!rake pedal pressing device- A< 17?40%-


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/l#g repair set 1B5 ?4711 A

After disconnecting the commanddevice from the h dra#lic #nit,alwa s place the valve t#betransport protection in theh dra#lic #nit.

B dra#lic #nits witho#t thetransport protection are notcovered b warrant .

1 -alve t#be transport

protection

% -/l#gs +15

-/l#gs +1%

Remove

Installationlocation:

*he command #nit is screwed tothe h dra#lic s stem #nit and isfo#nd in the right side of the

engine compartment.

AR I AB ! A"R! TC ! #"$! # P > )ydraulic unit! ser*o brake(brake cylinder + assembly o*er*iew > AB Bosch 20. > Command#nit for h,dra#lic #nit - remove and in"tall

Polo Mk4

Brake systems > AB ! A"R! TC ! #"$! # P > $%S ","tem component" on the front and rear axle" - remove and in"tall

A!) s stem components on the front and rear axles - remove andinstall

Polo Mk4Brake systems > AB ! A"R! TC ! #"$! # P > AB system components on the front and rear a3les + remo*e and install > !emove and in"tall

the front axle $%S " ,"tem component"

Remove and install the front axle A!) s stemcomponents
http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/abs_bosch_8.0/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/abs_bosch_8.0/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/abs_bosch_8.0/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/hydraulic_unit_servo_brake/brake_cylinder_assembly_overview/abs_bosch_8.0/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/


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1 -heel roller bearing

case

% -Internal hex headscrew

J7

m

-A!) speedsensor

Jis checked thro#gh self-diagnosis

J before inserting the sensor, o# m#st clean the internal hole s#rface and coat with'#bricating p#tt -< 555 ?65-. Refer to the 2 hemicals +an#al

Jremove and install

2 hapter

8 -over

plate

6 - Bexagonal head


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screw

J15

m

? -heel h#b with roller

bearing

Jthe A!) sensor ring is assembled in the

wheel h#b

Jremove and install 2 R#nning gear, axle, steeringO Rep. AB ! A"R! TC ! #"$! # P > AB system components on the front and rear a3les + remo*e and install > !emove and in"tallthe front axle $%S " ,"tem component"

Polo Mk4

Brake systems > AB ! A"R! TC ! #"$! # P > AB system components on the front and rear a3les + remo*e and install > Remo*e andinstall the front a3le AB system components > Front axle "peed "en"or - remove and in"tall

&ront axle speed sensor - remove andinstall

Remove

K'ift thevehicle.
http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/remove_and_install_the_front_axle_abs_system_components/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/remove_and_install_the_front_axle_abs_system_components/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/remove_and_install_the_front_axle_abs_system_components/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/remove_and_install_the_front_axle_abs_system_components/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/remove_and_install_the_front_axle_abs_system_components/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/remove_and_install_the_front_axle_abs_system_components/


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K"isengage the speed sensorcable connector -%-.

K Remove the screw -1- from the wheel roller bearing case.

KRemove the A!) speed sensorfrom the wheel roller bearingcase.

&or easier viewing, the brake discis represented as removed.

Install

K

!efore installing the speedsensor, clean the internals#rface of the hole and appl'#bricating /#tt -< 555 ?65 -aro#nd the sensor. )ee2 hemical +aterials +an#al .

K/lace the speed sensor in the

wheel roller bearing case andtighten the screw to 7 m.

Konnect the speed sensor with

the speed sensor cable.

K

*#rn the steering wheelcompletel to the left and to the

right and control the spaceavailable for the speed sensorcable.

Brake systems > AB ! A"R! TC ! #"$! # P > AB system components on the front and rear a3les + remo*e and install > Remo*e andinstall the front a3le AB system components > Front axle "peed "en"or - remove and in"tall

Polo Mk4

Brake systems > AB ! A"R! TC ! #"$! # P > AB system components on the front and rear a3les + remo*e and install > Remo*e andinstall the front a3le AB system components > /0 12 front "peed "en"or cable" - remove and in"tall

+ ?5 front speed sensor cables - remove andinstall


tiring harness repair set - A)

14@7 -e

K ote the coding in vehicles withcode radio eJ#ipment, reJ#est
http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/remove_and_install_the_front_axle_abs_system_components/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/remove_and_install_the_front_axle_abs_system_components/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/remove_and_install_the_front_axle_abs_system_components/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/remove_and_install_the_front_axle_abs_system_components/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/remove_and_install_the_front_axle_abs_system_components/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/remove_and_install_the_front_axle_abs_system_components/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/remove_and_install_the_front_axle_abs_system_components/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/remove_and_install_the_front_axle_abs_system_components/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/remove_and_install_the_front_axle_abs_system_components/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/remove_and_install_the_front_axle_abs_system_components/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/technical_data/technical_data/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/general_information_on_the_antilock_braking_system_(abs)/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_adr_tcs_edl_esp/abs_system_components_on_the_front_and_rear_axles_remove_and_install/remove_and_install_the_front_axle_abs_system_components/http://workshop-manuals.com/volkswagen/polo-mk4/brake_systems/abs_

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