Brake Fluid, Changing

Special tools and workshop equipment required

Vehicle Diagnostic Tester
Brake Charger/Bleeder Unit:VAS5234

Fig 1: Identifying Brake Charger/Bleeder Unit
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Brake Filling and Bleeding Equipment:VAS6860

Fig 2: Brake Filling and Bleeding Equipment :VAS6860
Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
Wrench - Brake Bleeder Set:VAS5519

Fig 3: Identifying Brake Bleeder Socket VAS 5519
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Brake Bleeding Tool Set:VAS6564

Fig 4: Identifying Tool Set : VAS6564 For Brake Bleeding
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Brake Bleeder Adapter:VAS5234/1

-- Pull the plenum chamber cover down far enough so that it possible to make cuts at the marked locations -arrow- without damaging the seal.

Fig 5: Locating Marks To Cut

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-- Cut the cover at the marked locations -arrow-.

-- Fold up the cover.

-- Remove brake fluid reservoir cap -1-.

Fig 6: Identifying Brake Fluid Reservoir Cover -1-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Insert the suction hose from the Brake Charger/Bleeder Unit through the screen -1- in the brake fluid reservoir to extract as much brake fluid -2- as possible.

Fig 7: Suction Hose From The Brake Charger/Bleeder Unit

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

NOTE:

Do not remove the screen inside the brake fluid reservoir.

After extracting, observe that no further brake fluid runs into the reservoir (the brake fluid level in the reservoir must align with the lower edge of the screen).

WARNING:

Do not reuse used / extracted brake fluid!

Observe the Operating Instructions for :VAS5234 !

-- Set the correct pressure using the Brake Charger/Bleeder Unit. Refer to Brake System, Bleeding .

-- Attach the adapter to the brake fluid reservoir.

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

-- Remove the caps from the brake caliper breather valves.

-- Connect the bleeder hose of collector bottle to rear bleeder valve, open bleeder screw, and allow the corresponding quantity to flow out (see table below). Close the bleeder valve. Refer to Rear Brake Caliper, Servicing for the tightening specification.

NOTE:

Use a suitable bleeder hose. It must seat tightly on the bleeder valve so that no air can get into the brake system.

Repeat work sequence on other side of vehicle at front.

NOTE:

Front brake calipers with two valves, first connect the outer bleeder valve and then the inner bleeder valve.

-- Connect collector bottle breather hose to the front bleeder valve. Then open the bleeder valve and allow the corresponding quantity to flow out (see table below). Breather valve closing. Refer to Front Brake Caliper, Servicing .

Repeat procedure on opposite rear.

Table: Sequence and Brake Fluid Capacity

Sequence: Decoupler, Brake Wheel Cylinder and Brake Caliper	Quantity of Brake Fluid that must Flow Out:
Vent connection decoupler (hybrid vehicles)	0.10 liter
Left front	0.25 liter
Right front	0.25 liter
Right rear	0.25 liter
Left rear	0.25 liter

Total quantity: approximately 1.0 liter including the extracted quantity from the brake fluid reservoir, on hybrid vehicles approximately 1.10 liters including the extracted quantity from the brake fluid reservoir.

-- Install the caps on brake caliper bleeder valves.

Additionally on Hybrid Vehicles:

Fig 8: Installed Location Of Breather Valve

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-- Remove the noise insulation. Refer to Noise Insulation .

-- Remove the cap -1- from the decoupler vent connection.

-- Insert the bleeder hose on the bleeder hose collector bottle. Open the bleeder valve and let the corresponding brake fluid capacity (see table) flow out.

-- Close the bleeder valve and remove the bleeder hose.

-- Connect the cap on the vent connection.

-- Connect the Vehicle Diagnostic Tester. Refer to VEHICLE DIAGNOSTIC TESTER, CONNECTING .

-- Perform a function test. Refer to [For transmission(s) 0C8] [For engine(s) CGFA] Clutch Mechanism, Servicing .

-- Install the noise insulation. Refer to Noise Insulation .

Continue for All Vehicles

-- Switch off the Brake Charger/Bleeder Unit.

-- Remove the filler hose from the adapter.

-- Remove the adapter from the brake fluid reservoir.

-- Check the brake fluid level and fill if necessary.

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

Fig 9: Identifying Brake Fluid Reservoir Cover -1-

Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.

-- Fold down the cover and push it under the seal.

-- Remove brake pedal actuator.

-- Check pedal pressure and brake pedal free play. Free play: maximum ¹ /₃ of pedal travel