Brake And Clutch System, Changing Brake Fluid

Special Tools And Workshop Equipment Required

Mini Torque Wrench:VAS6854

Fig 1: Identifying Mini Torque Wrench VAS 6854
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Brake Charger/Bleeder Unit:VAS5234

Fig 2: Identifying Brake Charger/Bleeder Unit
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Brake Filling and Bleeding Equipment:VAS6860

Fig 3: Brake Filling and Bleeding Equipment :VAS6860
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Brake Bleeding Tool Set - Insert Tool:VAS6564/9

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Brake Bleeding Tool Set:VAS6564

Fig 4: Identifying Tool Set : VAS6564 For Brake Bleeding
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WARNING:

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

Extract the Brake Fluid

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).

-- Remove the cap -1- from the brake fluid reservoir.

Fig 5: Identifying Brake Fluid Reservoir Cap

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-- Use the hose from the Brake Charger/Bleeder Unit to extract as much brake fluid as possible.

Fig 6: Suction Hose From The Brake Charger/Bleeder Unit

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WARNING:

Do not use extracted brake fluid again!

Bleeding the Brake System

-- Attach the adapter -1- to the brake fluid reservoir.

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Pay attention to the device owner's manual. Refer to :VAS5234 Owner's Manual.

-- Set the correct pressure using a :VAS5234 . Refer to HYDRAULIC SYSTEM .

-- Connect the hose on the :VAS5234 to the adapter -1-.

NOTE:

The bleed hose must fit tightly over the bleed screw to prevent air from getting into the brake system.

The brake fluid level in the reservoir must be high enough so that air cannot get into the brake system.

For RHD vehicles, begin with the front right.

By using the :VAS6564/9 the removal of the rear wheels is no longer necessary.

Front Axle

-- Remove the cap -1- from the breather valve on the left front brake caliper.

Fig 7: Identifying Bleeder Screw Cap

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-- Connect the collector bottle bleed hose -1- to the left front breather valve. Open the bleeder valve and let the corresponding brake fluid capacity (see table) flow out.

-- Close the bleeder valve. Torque. Refer to OVERVIEW - FRONT BRAKE CALIPER (CONVERTIBLE) .

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-- Install the cap on the left front brake caliper bleeder valve.

Repeat the same procedure on the right front side of the vehicle.

Rear Axle

-- Remove the cap -1- on the left rear brake caliper breather valve.

Fig 8: Identifying Bleeder Screw Cap (Rear)

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-- Connect the collector bottle breather hose -1- to the left rear bleeder valve.

Fig 9: Identifying Collector Bottle Bleeder Hose

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-- Open the bleeder valve and let the corresponding brake fluid capacity (see table) flow out. Close the bleeder valve.

-- Torque. Refer to OVERVIEW - REAR BRAKE CALIPER .

-- Install the cap on the left rear brake caliper bleed valve.

-- Repeat the same procedure on the right rear side of the vehicle.

Bleeding the Clutch Slave Cylinder

NOTE:

Only on vehicles with a manual transmission.

Remove The Air Filter Housing, If necessary.

Procedure:

-- Engine. Refer to the appropriate service information

-- Engine. Refer to AIR FILTER HOUSING, REMOVING AND INSTALLING [DDSA, DDSB] (CONVERTIBLE) / AIR FILTER HOUSING, REMOVING AND INSTALLING [CPLA, CPPA, CPKA, CPRA] (CONVERTIBLE) .

Fig 10: Identifying Clutch Slave Cylinder

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

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

Use the :VAG1238/B3 if necessary to bleed.

-- Open the breather valve.

-- Allow approximately 100 ml brake fluid to escape.

-- Close the bleeder valve.

-- Push the clutch pedal quickly from stop to stop 10 to 15 times.

-- Open the breather valve.

-- Allow another 50 ml brake fluid to escape.

-- Close the breather valve and install the dust cap.

-- Install The Air Filter Housing In Reverse Order Of Removal.

Tightening Specification	Nm
Breather Valve	4.5

NOTE:

For technical reasons it is possible the links do not go to the correct service information. If that is the case, please look up the procedure manually in the corresponding infomedia.

Sequence/Brake Fluid Quantity

Bleeder valve sequence:	Brake fluid amount which must flow out of the bleeder valves:
Bleeder valve sequence:
Brake caliper
left front	0.20 liter
right front	0.20 liter
Brake cylinder/brake caliper
Left rear	0.30 liter
Right rear	0.30 liter
Clutch slave cylinder	0.15 liter
Total quantity for automatic transmission including the extracted quantity from the brake fluid reservoir	approximately 1.00 liters
Total quantity for manual transmission including the extracted quantity from the brake fluid reservoir	approximately 1.15 liters

Automatic Transmission Total Capacity: Approximately 1.00 Liters

Manual Transmission Total Quantity: Approximately 1.15 liters

-- Move filler lever on :VAS5234 to position "B" (see operating instructions).

-- Remove the filler hose from the adapter.

-- Remove the adapter from the brake fluid reservoir.

-- Check the brake fluid level and fill if necessary. It must be between -1- and -2-.

Fig 11: Identifying Brake Fluid Level Marks On Reservoir

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

Fig 12: Identifying Brake Fluid Reservoir Cap

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-- Install the rear wheel if necessary. Refer to WHEEL BOLTS, TIGHTENING TO SPECIFICATION .

-- Perform a function test during the test drive.