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Workshop Manual
Amarok 2011
Brake systems
Edition 05.2013
AG. Volkswagen AG d
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Repair Group
00 - Technical data
45 - Anti-lock brake system
46 - Brakes - mechanism
47 - Brakes - hydraulics
AG. Volkswagen AG d
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Technical information should always be available to the foremen and mechanics, because their
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careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and t. Cop py
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
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Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Technical data for brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ce
le
un
pt
4 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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4.1 Assembly overview - front axle speed sensors G45 / G47 . . . . . . . . . . . . . . . . . . . . . . . . 14
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4.3 Removing and installing front axle speed sensors G45 / G47 . . . . . . . . . . . . . . . . . . . . . . 15
, is n
h re
4.4 Removing and installing rear axle speed sensors G44 / G46 . . . . . . . . . . . . . . . . . . . . . . 16
hole
spec
es, in part or in w
46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
t to the co
1 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.1 Assembly overview - front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
rrectness of i
1.2 Removing and installing brake pads or linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
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fo
3 Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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3.1 Assembly overview - parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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3.2 Removing and installing handbrake lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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34
3.3 Removing and installing front handbrake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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3.4 Removing and installing rear handbrake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
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47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1 Front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.1 Assembly overview - front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1.2 Removing and installing brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2 Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.1 General notes on brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.2 Pre-bleeding hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Contents i
Amarok 2011
Brake systems - Edition 05.2013
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4.3 Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
pt
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ii Contents
Amarok 2011
Brake systems - Edition 05.2013
00 Technical data
1 Technical data
(VRL005543; Edition 05.2013)
1.1 Technical data for brakes, page 1
thickness pt
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Brake disc, mm 26 ab
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wear limit
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4 Brake piston in mm 2 x 48
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spec
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2 Brake lining, mm 55
width
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thickness
com
tion in
thi
minimum thick
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ness (without
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carrier plate)
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3 Brake drum in Cop 295 py
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Brake drum, in 296.5
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wear limit
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1. Technical data 1
Amarok 2011
Brake systems - Edition 05.2013
2 Brake test
2.1 General information, page 2
2.2 Brake test, page 2
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The brake test must be performed on a regulated single-axle roller
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dynamometer.
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Regulated means that the speed of the brake test stand rollers is
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brake test.
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This prevents brake forces being transferred to the drive train.
Test speed should not exceed 6 km/h. Otherwise, the EDL control
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will activate the brakes if the rollers start at different speeds.
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The hydraulic unit -2- and control unit -1- form one component.
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Use Vehicle diagnostic tester for fault finding. Prote
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1. General information 3
Amarok 2011
Brake systems - Edition 05.2013
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If repairs cannot be carried out immediately, carefully cover or
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Only use lint-free cloths.
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spec
Only unpack replacement parts immediately prior to fitting.
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Only use genuine packed parts.
Do not work with compressed air if the system is open. Do not
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move the vehicle.
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Ensure that no brake fluid enters connectors. rm
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column between steer
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column switch.
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switch
After installing, perform
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Vehicle diagnostic
on in
tester.
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6 - Rear right speed sensor - G44- / rear left speed sensor - G46- C py
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Can be tested using Vehicle diagnostic tester. yri
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Removing and installing page 16 cted agen
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7 - Front right speed sensor - G45- / front left speed sensor - G47-
Can be tested using Vehicle diagnostic tester.
Removing and installing page 15
8 - Wheel bearing
ABS sensor ring is installed in wheel bearing
9 - Brake light switch - F-
Including brake pedal switch - F47- .
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Assembly overview page 7 .
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Removing and installing page 11
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1 - Brake servo
With brake master cylin
der and brake fluid res
ervoir
Removing and installing
page 51
2 - Connection for brake line
From primary piston cir
cuit of brake master cyl
inder to hydraulic unit.
14 Nm
3 - Connection for brake line
Hydraulic unit to primary
piston circuit of brake
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Identification: union nut yV
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with thread M12 x 1 ir se
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4 - ABS hydraulic unit - N55-
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ABS return flow pump -
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When replacing the hy
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logue (ETKA) .
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page 9 .
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Removing and installing ABS control unit - J104- without ABS hydraulic unit - N55- page 11 .
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5 - Bracket/frame
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7 - Connection for brake line
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To rear left wheel brake cylinder
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Identification: union nut with thread M12 x 1
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14 Nm
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3.2 Removing and installing ABS control
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unit - J104- and ABS hydraulic unit -
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Special tools and work
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shop equipment re urposes, in part or in wh
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Brake pedal depres
sor - V.A.G 1869/2-
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Torque wrench -
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V.A.G 1410-
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WARNING
Removing
Read out and note
the existing control
unit code.
Disconnect battery
Electrical system;
Rep. gr. 27 ; Discon
necting and recon
necting battery .
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Seal brake lines and threaded holes using sealing plugs from
pt
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Raise vehicle Maintenance ; Booklet ; Descriptions of work;
hole
spec
Raising vehicle .
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frame -2-.
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Installing
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Note
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Remove sealing plugs from new hydraulic unit only when the
corresponding brake line is to be fitted.
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If sealing plugs are removed too early from the hydraulic unit,
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Remove brake pedal depressor - V.A.G 1869/2- .
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Bleed brake system page 46 . Prote AG.
Location:
The ABS control unit - J104- is bolted to the ABS hydraulic unit -
N55- and is located on the left in the engine compartment.
WARNING
Removing
Note
Note
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The ABS control unit - J104- is removed downwards.olkswagen oes
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Installing
Installation is performed in reverse sequence; note the following:
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Note
has been disconnected. This does not affect the MK25E Vehicle
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diagnostic tester.
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Component Specified torque
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- N55-
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4 Sensors
4.1 Assembly overview - front axle speed sensors G45 / G47
, page 14
4.2 Assembly overview - rear axle speed sensors G44 / G46
, page 15
4.3 Removing and installing front axle speed sensors G45 /
G47 , page 15
4.4 Removing and installing rear axle speed sensors G44 /
G46 , page 16
1 - Bolt
20 Nm
2 - Brake disc
3 - Wheel hub
4 - Retaining ring
Secures wheel bearing
in wheel bearing hous n AG. Volkswagen AG do
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5 - Wheel bearing o
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-arrow- is installed in
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wheel bearing
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G47-
hole
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grease Electronic
Parts Catalogue (ET
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Removing and installing
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page 15
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8 - Bolt
at
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8 Nm
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1 - Brake backplate
Reset brake before re
moving brake drum
page 31
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150 Nm +90 ss c
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3 - Axle beam
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4 - Speed sensors - G44- / -
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sensor , clean inner sur
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face of hole and coat it
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with polycarbamide
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grease Electronic
Parts Catalogue (ET
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Removing and installing
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5 - Bolt
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8 Nm
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4. Sensors 15
Amarok 2011
Brake systems - Edition 05.2013
Removing
Raise vehicle Maintenance ; Booklet ; Descriptions of work;
Raising vehicle .
Pull connector -1- of speed sensor wire off speed sensor -2-.
Remove bolt -arrow- from wheel bearing housing.
Pull speed sensor -2- out of wheel bearing housing.
Installing
Installation is performed in reverse sequence; note the following:
Before inserting speed sensor , clean inner surface of hole,
and coat speed sensor all-round with polycarbamide grease
Electronic Parts Catalogue (ETKA) .
Insert speed sensor into hole in wheel bearing housing, and
tighten bolt.
Push connector of speed sensor wire onto speed sensor .
Turn steering to full left and right lock and check clearance to
speed sensor wire. . Volkswage n AG n AG d
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Specified torques Volks not
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4.1 Assembly overview - front
oris axle speed sensors G45 / nte
eo
th
G47 , page 14 s au ra
c
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pt
4.4 Removing and installing rear axle speed
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sensors - G44- / -G46-
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Special tools and workshop equipment required
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4. Sensors 17
Amarok 2011
Brake systems - Edition 05.2013
46 Brakes - mechanism
1 Front brakes
1.1 Assembly overview - front brakes, page 18
1.2 Removing and installing brake pads or linings,
page 19
1.3 Removing and installing brake caliper, page 22
Note
After replacing brake pads/linings, depress brake pedal firmly several times with
en AG. V
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wagen AGstationary so that
the brake pads/linings are properly seated in their normal operating
olks position.
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Use brake filling and bleeding equipment - VAS 5234- or upgrade
ir se kit and extraction unit - V.A.G 1869/4- nte to
extract brake fluid from brake fluid reservoir. aut
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Before removing a brake caliper or disconnecting a brake hose, fit brake pedal depressor - V.A.G 1869/2-
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With wheel bearing and
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wheel hub
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2 - Bracket
For brake hose and
speed sensor wire
rrectness of i
3 - Bolt
l purpos
nform
ercia
9.5 Nm
m
a
com
t
4 - Splash plate
ion in
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5 - Brake disc
thi
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Internally ventilated do
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Thickness: 28 mm t. Cop py
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Wear limit: 26 mm.
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When worn, renew on
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both sides of axle.
AG.
8 - Brake pads
Thickness: 12.5 mm not including backplate.
Pad wear limit: 2 mm without backplate (remaining pad thickness)
Check thickness Maintenance ; Booklet ; Descriptions of work; Brake system: Conducting visual
examination for leaks and damage
Always replace on both sides
Removing and installing page 19
9 - Pad retainer
Always renew when changing pads.
10 - Brake carrier
With guide pins and protective caps
Bolt to wheel bearing housing.
Supplied as genuine part, assembled with sufficient grease on guide pins.
If protective caps or guide pins are damaged, install repair kit and use lubricant sachet supplied to lu
bricate guide pins
Installation position of guide pins page 19
11 - Brake caliper
Removing and installing page 22
12 - Bolt
Always renew after removing
65 Nm
13 - Brake hose
Install without twisting
Specified torque when being secured to brake caliper: 14 Nm (pipe with union nut).
Specified torque when being secured to brake caliper: 17 Nm (threaded pipe).
14 - Bolt
Always renew after removing n AG. Volkswagen AG do
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150 Nm +90 by
Volk ot g
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ris tee
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Installation position of guide pins
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Note
h re
hole
spec
es, in part or in w
If protective caps -2- or guide pins -1- and -4- are damaged, install
t to the co
repair kit and use lubricant sachet supplied to lubricate guide pins.
rrectness of i
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
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ng
t.
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linings
Co
Cop py
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Special tools and workshop equipment required cop Vo
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Prote AG.
1. Front brakes 19
Amarok 2011
Brake systems - Edition 05.2013
n AG. Volkswagen AG do
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Caution
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du
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ab
wit
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hole
Raising vehicle .
t to the co
Note
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atio
om
n in
or c
thi
te
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t.
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Cop py
t. rig
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pyri by
Vo
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by
cted agen
Prote AG.
Removing
Remove bolts -arrows- for securing brake caliper with spanner
-1- (15 mm). When doing this, counterhold on guide pin using
open jaw spanner -2- (21 mm).
Remove brake caliper from brake carrier.
Secure brake caliper with wire so that the weight of the brake
caliper does not stress or damage the brake hose.
ce
le
un
pt
an
d
itte
y li
Do not blow out brake system with compressed air; the result
rm
ab
ing dust constitutes a health hazard!
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
Note
t to the co
Only use methylated spirits to clean brake caliper housing.
rrectness of i
Installing
l purpos
Before inserting new brake pads, press piston back into cylinder
using piston resetting tool - T10145- . Before pressing piston
m
back, draw off brake fluid from brake fluid reservoir with bleeder
com
tion in
thi
do
r
rp
cum
en
ng
1. Front brakes 21
Amarok 2011
Brake systems - Edition 05.2013
ce
le
un
pt
an
d
itte
Fit pad retainers with chamfered projection -arrows- outward
y li
rm
ab
on brake carrier.
pe
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
a
com
tion in
Fit brake caliper onto brake carrier and tighten securing bolts.
r
te o
thi
s
iva
Fit wheels.
do
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rp
cum
fo
en
ng
t.
yi Co
Note Cop py
t. rig
gh ht
pyri by
After replacing brake pads/linings, depress brake pedal firmly
co Vo
by lksw
cted
several times with vehicle stationary so that the brake pads/
agen
Prote AG.
linings are properly seated in their normal operating position.
Check brake fluid level after changing brake pads.
Specified torques
1.1 Assembly overview - front brakes, page 18
Wheels, tyres; Specified torque for wheel bolts Rep. gr. 44 ;
Specified torque for wheel bolts .
ce
le
un
pt
an
d
itte
y li
Note
erm
ab
ility
ot p
wit
This procedure applies only to exchanging or the following repair is n
h re
work on the brake caliper.
ole,
spec
urposes, in part or in wh
t to the co
Raising vehicle .
Remove front wheels.
rrectne
Connect bleeder bottle hose to brake caliper bleeder valve and
open bleeder valve.
ss o
cial p
f
Then apply brake pedal actuator - V.A.G 1869/2- .
inform
mer
atio
om
n
c
i
or
n thi
e
sd
va
-1- (15 mm). When doing this, counterhold on guide pin using
i
o
pr
cum
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en
ng
t.
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Remove brake caliper from brake carrier. Cop py
t. rig
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yri
Installing p by
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cted agen
Installation is performed in reverse sequence; note the following: Prote AG.
Note
Specified torques
1.1 Assembly overview - front brakes, page 18
Wheels, tyres; Specified torque for wheel bolts Rep. gr. 44 ;
Specified torque for wheel bolts .
1. Front brakes 23
Amarok 2011
Brake systems - Edition 05.2013
2 Rear brakes
2.1 Assembly overview - rear brakes, page 24
2.2 Removing and installing brake carrier, page 27
2.3 Removing and installing brake shoes, page 28
2.4 Resetting drum brakes, page 31
2.5 Removing and installing wheel brake cylinder, page 33
Note
After renewing wheel brake cylinder, brake carrier and brake shoes, basic setting of the adjuster needs to
be performed page 31 . Then, with vehicle stationary and brake drum installed, depress brake pedal
firmly 10 times so that the brake shoes are properly seated in their normal operating position.
After work for which the brake system had to be opened, bleed the brake system with brake charge and
bleed system - VAS 5234- or extraction unit -V.A.G 1869/4- .
Before removing a wheel brake cylinder or brake backplate or disconnecting a brake line from the wheel
brake cylinder, fit brake pedal depressor - V.A.G 1869/2- (release pressure in system).
G. Volkswagen nA AG do
wage es n
Volks ot g
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ed ran
1 - Bolt oris tee
th or
au ac
20 Nm ss
ce
e
nl
pt
2 - Brake drum
du
an
itte
y li
ab
surface.
spec
es, in part or in w
295 mm
Wear limit: 296.5 mm.
rrectness of i
at
om
io
in t
or
en
ng
page 35
7 - Handbrake cable rear right
To week 25/2011: secured on rear axle with a spring
From week 25/2011: revised handbrake cable, spring discontinued
Removing and installing page 36
8 - Adjustment nut
Adjusting handbrake page 38 .
9 - Handbrake cable rear left
To week 25/2011: secured on rear axle with a spring
From week 25/2011: revised handbrake cable, spring discontinued
Removing and installing page 36
10 - Bolt
For rear handbrake cable on brake carrier
9.5 Nm
11 - Bolt n AG. Volkswagen AG do
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For wheel by Vbrake cylinder on brake carriert gua
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8 Nm ho
ris tee
t or
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12 - Cap
ss c
ce
le
pt
an
d
itte
Reset brake shoes through this opening before removing brake drum
y li
rm
ab
pe
ility
13 - Brake line
ot
wit
, is n
14 Nm
h re
hole
spec
14 - Brake backplate
es, in part or in w
16 - Bolt
Self-locking (micro-encapsulated)
m
a
com
tio
thi
do
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cum
Note
fo
en
ng
t.
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op
Threaded holes into which self-lock
C py
t. rig
gh
ing bolts or bolts with locking fluid
ht
pyri by
have been screwed must be
co Vo
by lksw
cted agen
cleaned (e.g. using a thread chas
Prote AG.
er). Otherwise, there is a risk that
bolts will shear off when removed
once again.
30 Nm
17 - Brake shoe
Installed at rear in direction of travel
Wear limit page 1
Removing and installing page 28
18 - Brake shoe with lever for handbrake
Installed at front in direction of travel
2. Rear brakes 25
Amarok 2011
Brake systems - Edition 05.2013
Wear limit page 1
Removing and installing page 28 AG. Volkswagen AG d
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olksw not
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19 - Compression spring d b ara
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20 - Spring plate aut ra
c
ss
To remove, push against compression spring and turn through 90.
ce
le
un
pt
an
d
21 - Plunger rod
itte
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rm
ab
Note correct installation position page 30
pe
ility
ot
wit
, is n
Note
h re
hole
spec
Adjusters on plunger rod differ
es, in part or in w
t to the co
according to whether they have
a right-hand or left-hand thread,
depending on the installation po
sition.
rrectness of i
Adjuster marked L (left-hand
l purpos
nform
ercia
a
com
tio
Note installation position: steeply offset side points towards lever for handbrake.
n in
r
te o
thi
Removing and installing page 30
s
iva
do
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23 - Adjuster spring
cum
fo
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t.
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Cop py
24 - Lever
t. rig
gh ht
pyri by
Secures adjusters on plunger rod to prevent them from turning back.
co Vo
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cted agen
Prote
Must be carefully pushed away from adjuster (towards brake drum) when brake shoes are reset.
AG.
ce
le
un
pt
an
d
itte
Note
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rm
ab
pe
ility
Renew wheel brake cylinder in case of leaks or if damaged.
ot
wit
, is n
h re
hole
Specified torque
spec
es, in part or in w
t to the co
Component Specified torque
Bleeder valve in wheel brake 8 Nm
cylinder
rrectness of i
l purpos
nform
ercia
Removing
m
a
com
tio
Raising vehicle .
n in
r
te o
thi
Remove rear wheels.
s
iva
do
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rp
c
Resetting brake and removing brake drum page 31 .
um
fo
en
ng
t.
yi
Remove brake shoes page 28 .
Co
Cop py
t. rig
gh
Remove wheel brake cylinder page 33 .
ht
pyri by
Vo
o
by c lksw
Remove rear axle shaft Running gear, axles, steering; Rep.
cted agen
Prote AG.
gr. 42 ; Rear axle shafts .
2. Rear brakes 27
Amarok 2011
Brake systems - Edition 05.2013
Remove bolt -A- and take brake carrier off axle beam.
Installing
Installation is performed in reverse sequence; note the following:
Note
ce
le
un
pt
Rear axle shafts; Assembly overview - rear axle shafts
an
d
itte
y li
erm
ab
view - rear axle shafts .
ility
ot p
wit
Wheels, tyres; Specified torque for wheel bolts Rep. gr. 44 ;
is n
h re
Specified torque for wheel bolts .
ole,
spec
urposes, in part or in wh
t to the co
Special tools and workshop equipment required
rrectne
Hook - 3438-
ss o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Lubricating paste Electronic Parts Catalogue (ETKA) . Prote AG.
Removing
Raise vehicle Maintenance ; Booklet ; Descriptions of work;
Raising vehicle .
Remove rear wheels.
Resetting brake and removing brake drum page 31 .
AG. Volkswagen AG d
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Removal and installation
orise
of brake shoes is shown for left side
nte
e
of rear axle only.
ut Brake shoe removal and installation on right or a
h
a
side are analogous.
ss c
ce
le
un
pt
Use only methylated spirits for cleaning the brake system.
an
d
itte
y li
erm
ab
ility
ot p
WARNING
wit
is n
h re
ole,
spec
Do not blow out brake system with compressed air; the result
urposes, in part or in wh
t to the co
Turn back adjustment nut -5- on front handbrake cable -1-.
rrectnes
Note
s o
cial p
f inform
-Pos. 2 4- are not relevant.
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Detach adjuster spring -A- from front brake shoe and remove
it from lever -B- -arrow-.
Remove lever -B-.
2. Rear brakes 29
Amarok 2011
Brake systems - Edition 05.2013
Removing and installing upper return spring -1- and plunger rod
-2- from brake shoes.
Turn back pinion of adjuster -arrow A-.
Note
ce
e
nl
pt
du
an
Unhook complete plunger rod -2- and upper return spring -1-
itte
y li
from brake shoes -3- and -4-.
erm
ab
ility
ot p
wit
, is n
h re
Place thermoclip -6- and end piece -7- onto plunger rod -5-
hole
spec
with adjuster. Make sure that projection -arrow C- is inserted
es, in part or in w
t to the co
Hook in upper return spring.
rrectness of i
Note installation position: steeply offset side of spring points
in direction of travel, towards lever for handbrake -4-.
l purpos
nf
ercia
orm
m
Installing
atio
om
n in
or c
sd
a
-B-.
iv
o
r
rp
cu
o
en
ng
t.
yi
-arrow 2- and on brake carrier -arrow 1- (qty. 6 distributed
Co
op py
around circumference) with lubricating paste Electronic t. C rig
gh ht
Parts Catalogue (ETKA) . yri
p by
co Vo
by lksw
cted
Guide brake shoes in together with plunger rod and return
agen
Prote AG.
spring from top between wheel hub and wheel brake cylinder.
Fit brake shoes onto wheel cylinder pistons.
Note
ce
le
un
pt
an
d
Note
itte
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erm
ab
ility
ot p
wit
is n
h re
If a used plunger rod is installed, it must be checked for ease
ole,
spec
of movement and cleaned if necessary.
urposes, in part or in wh
t to the co
rrectne
Perform basic setting.
Use adjuster pinion -1- to set brake shoes to dimension
ss
-a- = 294 mm.
o
cial p
f inform
mer
Caution
atio
om
n
c
i
or
n
If distance -a- is too small then plunger rod might slip out of
thi
e
sd
iva
o
function.
pr
cum
r
fo
en
ng
t.
yi Co
op py
Install brake drum.
t. C rig
gh ht
pyri by
Vo
o
Firmly depress brake pedal 10 times.
c by lksw
cted agen
Prote AG.
Fit wheels.
Adjust handbrake page 38 .
Specified torques
2.1 Assembly overview - rear brakes, page 24
Wheels, tyres; Specified torque for wheel bolts Rep. gr. 44 ;
Specified torque for wheel bolts .
2. Rear brakes 31
Amarok 2011
Brake systems - Edition 05.2013
ce
e
nl
pt
du
an
itte
y li
erm
ab
Unclip sealing cover -arrow- from brake drum.
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nf
ercia
orm
m
atio
Pass a hook , e.g. -3438- through a threaded hole for wheel
om
n in
or c
-direction of arrow-.
thi
te
sd
iva
cu
o
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
Note
ce
1
e
tighten one then the other by a / turn at a time. 2
nl
pt
du
an
itte
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Check wear limit of brake drum using brake drum calliper
erm
ab
gauge - VAS 6787- .
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
2.5 Removing and installing wheel brake
cylinder
l purpos
nform
ercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
Removing
Raise vehicle Maintenance ; Booklet ; Descriptions of work;
Raising vehicle .
Remove rear wheels.
Connect bleeder bottle hose to wheel brake cylinder bleeder
valve and open bleeder valve.
Then apply brake pedal actuator - V.A.G 1869/2- .
Following this, close bleeder valve and remove bleeder bottle.
Remove brake line -1- from wheel brake cylinder.
Resetting brake and removing brake drum page 31 .
Remove brake shoes page 28 .
Remove bolts -2- for wheel brake cylinder on brake carrier and
take off wheel brake cylinder.
Installing
Installation is performed in reverse sequence; note the following:
Install brake shoes and brake drum page 28 .
Bleed brake system page 46 .
Specified torques
2.1 Assembly overview - rear brakes, page 24
Wheels, tyres; Specified torque for wheel bolts Rep. gr. 44 ;
Specified torque for wheel bolts .
2. Rear brakes 33
Amarok 2011
Brake systems - Edition 05.2013
3 Handbrake
3.1 Assembly overview - parking brake, page 34
3.2 Removing and installing handbrake lever, page 34
3.3 Removing and installing front handbrake cable,
page 35
3.4 Removing and installing rear handbrake cable,
page 36
3.5 Adjusting parking brake, page 38
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
er
o
n
c
i
or
n thi
te
Removing
sd
iva
o
pr
cum
r
en
ng
ce
le
un
pt
-1-.
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
Handbrake lever -1- is in its lowest position, and is not applied.
cial p
f inform
Pull connector -3- off handbrake warning switch - F9- -2-.
mer
atio
m
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Handbrake 35
Amarok 2011
Brake systems - Edition 05.2013
Unhook front handbrake cable -A- from bracket -B- and pull
out downwards with grommet -arrow-.
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
rise nte
tho eo
au ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
Unscrew adjustment nut -5- from front handbrake cable -1-.
urposes, in part or in wh
t to the co
Note
rrectne
Handbrake cables at rear left -2- and right -3- remain in compen
sator -4-.
ss o
cial p
f i
Using pliers, press together both locking projections on cable
nform
support bracket -arrow A- of front handbrake cable, and re
mer
atio
move handbrake cable -1- from cable support bracket.
om
n
c
i
Installing
or
n thi
te
sd
a
o
pr
cum
r
fo
en
ng
t.
yi
handbrake cable must be horizontal after installation.
Co
Cop py
t. rig
gh
Install handbrake lever page 34 .
ht
pyri by
Vo
co lksw
by
cted
Adjust handbrake page 38 .
agen
Prote AG.
Specified torques
3.1 Assembly overview - parking brake, page 34
Installing centre console General body repairs, interior;
Rep. gr. 68 ; Compartments, covers and trims; Installing cen
tre console .
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
Remove cable ties -arrows- for speed sensor wire from hand
es, in part or in w
brake cable.
t to the co
Remove bolts -A- and take handbrake cable off brake carrier.
rrectness of i
l purpos
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
o
r
rp
cu
m
f
en
ng
3. Handbrake 37
Amarok 2011
Brake systems - Edition 05.2013
Note
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
right -3- and hook it into compensator -4-.
es, in part or in w
t to the co
Locking projections on cable support bracket -arrow B- of rear
handbrake cables must be horizontal after installation.
rrectness of i
Connect compensator -4- to front handbrake cable -1-.
l purpos
nf
ercia
or
3.1 Assembly overview - parking brake, page 34
m
m
atio
om
sd
iva
o
r
rp
cu
o
m
f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
n AG. Volkswagen AG do
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ir se tee
tho
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ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.
3. Handbrake 39
Amarok 2011
Brake systems - Edition 05.2013
4 Brake pedal
4.1 Assembly overview - brake pedal, page 40
4.2 Removing and installing brake pedal, page 41
ce
e
nl
pt
du
an
itte
y li
Grease all bearing points with polycarbamide grease before in
erm
ab
stalling Electronic Parts Catalogue (ETKA) .
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
Removing and installing
page 41
rrectness of i
2 - Pin
l purpos
nform
ercia
3 - Nut
m
io
moving n
c
in t
or
ber bulkhead
um
for
en
g
25 Nm
n
t.
yi Co
Cop py
t.
4 - Nut
rig
gh ht
pyri by
Vo
Always renew after re
o
by c lksw
cted agen
moving Prote AG.
ce
e
pt
du
an
itte
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erm
ab
ility
ot p
Note
wit
, is n
h re
hole
spec
Nuts on left side are concealed by steering column.
es, in part or in w
t to the co
Remove pedal cluster/brake pedal -3-.
Installing
rrectness of i
Installation is performed in reverse sequence; note the following:
l purpos
Push pin -2- from right to left into yoke head/brake booster on orm
m
atio
n in
or c
Specified torques
thi
te
sd
iva
cu
o
m
f
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Prote AG.
4. Brake pedal 41
Amarok 2011
Brake systems - Edition 05.2013
47 Brakes - hydraulics
AG. Volkswagen AG d
agen oes
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1 Front brake caliper ol not
V gu
d by ara
ise nte
or
1.1 Assembly overview - frontautbrake caliper, page 42
h eo
ra
ss c
1.2 Removing and installing brake caliper piston, page 43
ce
le
un
pt
an
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ab
pe
ility
ot
wit
, is n
Note
h re
hole
spec
When carrying out repairs, install all parts supplied in repair kit.
es, in part or in w
t to the co
Use only methylated spirits for cleaning the brake.
Apply thin coat of assembly paste to brake cylinder, piston and seal Electronic Parts Catalogue (ETKA) .
rrectness of i
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1 - Dust cap
nform
ercia
2 - Bleeder valve
m
a
com
tio
ply thin coat of assembly
n in
r
thi
tronic Parts Catalogue
s
iva
do
r
(ETKA) .
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12 Nm
n
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3 - Brake hose
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Specified torque when Prote AG.
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Piston resetting appliance - T10145-
ility
ot p
wit
is n
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spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
Removing
n
c
i
or
n thi
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sd
va
air.
i
o
pr
cum
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fo
en
ng
Note
Installing
Installation is performed in reverse sequence; note the following:
Apply a thin coat of assembly paste to pistons and seals before
inserting Electronic Parts Catalogue (ETKA) .
Insert oil seals in brake caliper housing.
AG. Volkswagen AG d
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spec
Using removal wedge - 3409- , insert inner sealing lip into cyl
es, in part or in w
t to the co
inder groove.
When doing this, hold piston in front of brake caliper housing.
rrectness of i
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nf
ercia
orm
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2 Hydraulic system
2.1 General notes on brake fluid, page 45
2.2 Pre-bleeding hydraulic system, page 46
2.3 Bleeding hydraulic system following standard procedure,
page 48
2.4 Subsequent bleeding of hydraulic system, page 48
2.5 Testing for leaks, page 48
WARNING
pt
du
an
itte
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erm
ab
ility
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, is n
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hole
spec
es, in part or in w
t to the co
rrectness of i
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mercia
at
om
ion
c
in t
or
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ate
do
priv
cum
for
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Cop py
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Prote AG.
2. Hydraulic system 45
Amarok 2011
Brake systems - Edition 05.2013
Caution
ce
le
un
pt
an
d
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ab
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ility
ot
partner.
wit
, is n
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hole
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es, in part or in w
t to the co
Note
changing
a
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tion in
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Brake filling and bleeding equipment - VAS 5234- or
Co
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Note
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Note
erm
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pre-bled first.
spec
es, in part or in w
t to the co
Bleeding sequence:
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neously.
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at
io
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or
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Connect Vehicle diagnostic tester, and select function.
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Then bleed brake system as normal page 48 .
by lksw
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Prote AG.
2. Hydraulic system 47
Amarok 2011
Brake systems - Edition 05.2013
This bleed sequence must be carried out 5 times per brake caliper
pt
du
an
itte
ab
Bleeding sequence:
ility
ot p
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spec
t to the co
A road test must be carried out after the brakes have been bled.
When doing this an ABS regulation must be performed at least
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once!
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at
ion
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ate
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Prote AG.
2. Hydraulic system 49
Amarok 2011
Brake systems - Edition 05.2013
Caution
1 - Cap
2 - Brake fluid level warning
contact - F34-
3 - Brake fluid reservoir
4 - Connection
For supply hose to mas
ter cylinder
Only for vehicles with
n AG. Volkswagen AG do
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5 - Vacuum hose ir se
d ran
tee
tho
or
6 - Sealing plug au ac
ss
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7 - Brake booster
nl
pt
du
an
itte
ab
essary vacuum is ob
ility
ot p
h re
pump.
hole
spec
Functional check:
l purpos
atio
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c
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booster is functioning
o
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14 - Brake line
un
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ab
14 Nm
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15 - Splash plate
h re
ole,
spec
16 - Nut
urposes, in part or in wh
25 Nm
17 - Brake line
rrectne
14 Nm
s o
cial p
f i
18 - Pin
nform
mer
n
c
i
or
n thi
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19 - Sealing plug
t
sd
iva
o
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Moisten with brake fluid and press into brake fluid reservoir.
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3.2 Removing and installing brake booster
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Special tools and workshop equipment required Prote AG.
Removing
Vehicles with air conditioning system:
. Volkswagen AG
Pull connector -1- off refrigerant line -2-.kswagen AG does
not
Vol
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Remove refrigerant line -2- from isplenum
ed b chamber bulkhead ara
nte
-arrow- and carefully tie up slightly
thor
higher. eo
au ra
s c
Continuation for all models: s
ce
e
nl
pt
du
an
itte
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tact - F34- .
erm
ab
ility
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Remove engine control unit -5- with bracket.
hole
spec
Unclip electrical connector -6- from wiring retainer and tie to
es, in part or in w
t to the co
one side.
Pull vacuum hose -7- out of brake booster.
rrectness of i
Lay out a sufficient number of lint-free cloths under brake
master cylinder.
l purpos
Draw off as much brake fluid as possible from brake fluid res
ervoir using brake filling and bleeding equipment - VAS 5234-
nf
ercia
atio
m
n in
or c
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Detach supply hose -1- for clutch master cylinder and seal.
t
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Pull connector -3- off brake light switch - F- . t. Cop py
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Unscrew brake lines -2- and -4- from brake master cylinder yri
p by
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and seal brake lines using sealing plugs from repair kit part
c by lksw
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number 1H0 698 311 A.
Prote AG.
Remove securing spring -1- from pin -2- for yoke head/brake
booster connection on brake pedal.
Pull out pin -2-.
Remove nuts -arrows B-, total qty. 4, on both sides of pedal
mechanism/brake pedal.
Note
ce
inder, page 50
e
nl
pt
du
an
itte
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erm
ab
ility
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, is n
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cylinder
hole
spec
es, in part or in w
t to the co
Brake filling and bleeding equipment - VAS 5234-
rrectness of i
l purpos
nf
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orm
m
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Torque wrench - V.A.G 1331-
un
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hole
spec
es, in part or in w
t to the co
rrectness of i
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nform
ercia
Removing
m
a
Disconnect connector -3- from brake fluid level warning con
com
tio
tact - F34- .
n in
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s
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um
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The other items in the illustration are not relevant. Cop py
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Removing and installing brake master cylinder together with p by
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brake fluid reservoir.
lksw
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Prote AG.
Detach supply hose -1- for clutch master cylinder and seal.
Continuation for all models:
Pull connector -3- off brake light switch - F- .
Unscrew brake lines -2- and -4- from brake master cylinder
and seal brake lines using sealing plugs from repair kit part
number 1H0 698 311 A.
Remove nuts -arrows- for brake master cylinder from brake
booster.
Remove heat shield (if installed) -5-.
Carefully take brake master cylinder -6- out of brake booster.
Installing
Installation is performed in reverse sequence; note the following:
When assembling brake master cylinder with brake booster,
make sure plunger rod is properly positioned in brake master
cylinder.
After installation, brake system page 46 and clutch mecha
nism need to be bled Power transmission; Rep. gr. 30 ;
Bleeding clutch mechanism .
Specified torques
3.1 Assembly overview - brake booster/brake master cyl
inder, page 50
Note
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Remove bolt -1- from brake master cylinder.
rm
ab
pe
ility
Pull brake light switch - F- -2- off the brake master cylinder
ot
wit
underneath and out of the clip at the top -arrow-.
, is n
h re
hole
Installing
spec
es, in part or in w
t to the co
Tighten bolt -1-.
rrectness of i
Specified torques
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
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fo
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t.
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Cop py
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rig ht
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Prote AG.
4 Brake lines
4.1 Assembly overview - flanging tool, page 56
4.2 Required tools, page 57
4.3 Repairing brake lines, page 58
AG. Volkswagen AG d
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4.1 Assembly overview - flanging btool w oes
olks not
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1 - Flanging tool upper part au ra
c
ss
ce
e
Unbolt to change flang
nl
pt
du
ing jaws .
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itte
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ab
2 - Fastening for handle
ility
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, is n
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hole
spec
es, in part or in w
3 - Securing bolt
t to the co
For flanging tool upper
part
rrectness of i
4 - Grub screws for flanging
l purpos
jaws
Centring and holding
flanging jaws .
nform
ercia
at
bolt, 2 mm
om
ion
c
in t
or
5 - Flanging jaws
his
ate
do
riv
Various
p
cum
or
Assembly instructions
f
en
ng
t.
page 56
yi Co
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Note
ce
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nl
The use of flanging tool V.A.G. 1356 is not permitted due to the
pt
du
an
itte
coating and the diameter of the black brake lines.
y li
erm
ab
ility
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wit
, is n
Note
h re
hole
spec
Brake pipes may only be bent up to max. 90. They otherwise
es, in part or in w
kink or reveal deformations which impermissibly constrict the
t to the co
pipe cross-section.
Preferably separate brake lines at underbody.
rrectness of i
The positions of the intermediate pieces must be selected so
l purpos
nform
mercia
at
Special tools and workshop equipment required
om
ion
c
in t
Flanging tool for brake lines - VAS 6056-
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
t. rig
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Vo
co lksw
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cted agen
Prote AG.
4. Brake lines 57
Amarok 2011
Brake systems - Edition 05.2013
ce
e
readjusted!
nl
pt
du
an
itte
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4 - Set of grips with plastic jaws
erm
ab
- VAS 6056/4-
ility
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wit
5 - Pipe bending tool - VAS
, is n
h re
6056/5-
hole
spec
6 - Special wrench, 6 mm
es, in part or in w
t to the co
7 - Flanging jaws - VAS
6056/7-
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
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Cop py
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Vo
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Prote AG.
Note
Remove set of grips and slide union bolt -D- onto brake line.
AG. Volkswagen AG d
agen oes
olksw not
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ara
ed
ris nte
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aut ra
ss c
ce
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nl
pt
du
an
itte
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erm
wit
, is n
h re
Note
hole
spec
es, in part or in w
socket head bolts are tightened, or the flange will not be formed
correctly.
rrectness of i
Clamp brake line in flanging tool until brake line can no longer
l purpos
be moved. Then fold up stop -A- and use angled driver -C- to
tighten hexagon socket head bolts in diagonal sequence.
nf
ercia
orm
m
atio
n in
c
thi
te
sd
a
o
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Check brake line and flanging head.
C py
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Briefly flush the section of brake line remaining in the vehicle:
co Vo
by lksw
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Prote AG.
Connect brake filling and bleeding unit - VAS 5234- , connect
bleeder bottle hose to brake line flange and allow brake filling
and bleeding unit - VAS 5234- to run briefly until a little brake
fluid has run through.
Blow out new brake line to be inserted with compressed air.
4. Brake lines 59
Amarok 2011
Brake systems - Edition 05.2013
ce
le
un
pt
an
d
itte
y li
erm
ab
ility
ot p
wit
is n
h re
ole,
spec
urposes, in part or in wh
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
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Cop py
t. rig
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Vo
co lksw
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Prote AG.