Volkswagen Touareg 2010 Instruction manual

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Workshop Manual
Touareg 2010 ➤
Brake systems
Edition 05.2011
Service
Service Department. Technical Information

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List of Workshop Manual Repair GroupsList of Workshop Manual
Repair GroupsList of Workshop Manual Repair Groups
Repair Group
00 - Technical data
45 - Anti-lock brake system
46 - Brakes - mechanism
47 - Brakes - hydraulics
Technical information should always be available to the foremen and mechanics, because their
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
Service
All rights reserved.
No reproduction without prior agreement from publisher.
Copyright © 2011 Volkswagen AG, Wolfsburg D3E80297240

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Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Brake allocation via PR No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Example of a vehicle data sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Brake master cylinder and brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.2 Testing vehicles with no electric differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.3 Testing vehicles with electric differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3.4 Testing the electromechanical parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1 General notes for anti-lock brake system (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Notes for repair work on the ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Connecting VAS 5051 and selecting functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4 Electrical/electronic components and locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Assembly overview - hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.1 ABS MK 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6 Removing and installing parts of ABS system on front and rear axle . . . . . . . . . . . . . . . . 23
6.1 Removing and installing speed sensor on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2 Removing and installing parts of ABS system on rear axle . . . . . . . . . . . . . . . . . . . . . . . . 24
6.3 Removing and installing speed sensor on rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7 Removing and installing parts of ESP system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.1 Removing and installing ESP sensor unit G419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7.2 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1 Repairing front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.1 Assembly overview - front brake, Brembo 17" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.4 Assembly overview - front brake, Brembo 18" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.5 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.6 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2 Repairing rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.1 Assembly overview - rear brake caliper, 17" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.2 Removing and installing brake pads/linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.3 Removing and installing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.4 Removing and installing brake shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.5 Adjusting air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3 Repairing thread in brake caliper connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.1 Work instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4 Overview of electromechanical parking brake components . . . . . . . . . . . . . . . . . . . . . . . . 57
4.1 Removing and installing control unit for electromechanical parking brake J540 . . . . . . . . 58
4.2 Removing and installing parking brake motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5 Assembly overview - brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.1 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Touareg 2010 ➤
Brake systems - Edition 05.2011
Contents i

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5.2 Removing and installing brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.3 Adjusting brake pedal position sender G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1 Repairing front brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.1 Assembly overview - brake caliper, Brembo 17" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.2 Assembly overview - brake caliper, Brembo 18" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
1.3 Removing and installing piston for 17" and 18" Brembo caliper . . . . . . . . . . . . . . . . . . . . . . 68
2 Repairing rear brake calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.1 Assembly overview - brake caliper, Brembo 17" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.2 Removing and installing rear brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3 Pressurised leak test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4 Bleeding brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.1 Bleeding brake system with brake filling and bleeding equipment VAS 5234 . . . . . . . . . . 75
4.2 Changing brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
5 Assembly overview - brake servo/brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5.1 Removing and installing brake light switch F , left-hand drive . . . . . . . . . . . . . . . . . . . . . . 79
5.2 Removing and installing brake light switch F , right-hand drive . . . . . . . . . . . . . . . . . . . . . . 80
6 Brake servo vacuum supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6.1 Overview - vacuum pump for brake servo (diesel vehicles) . . . . . . . . . . . . . . . . . . . . . . . . 82
6.2 Assembly overview - vacuum pump for brakes V192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
6.3 Removing and installing vacuum line with vacuum sender G608 , right-hand drive model
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.4 Checking brake servo vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
6.5 Checking non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
7 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
7.1 Removing and installing brake master cylinder, left-hand drive . . . . . . . . . . . . . . . . . . . . . . 91
7.2 Removing and installing brake master cylinder, right-hand drive vehicle . . . . . . . . . . . . . . 92
8 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
8.1 Removing and installing brake servo, left-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
8.2 Removing and installing brake servo, right-hand drive vehicle . . . . . . . . . . . . . . . . . . . . . . 98
9 Repairing brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
9.1 Assembly overview - flanging tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
9.2 Work instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Touareg 2010 ➤
Brake systems - Edition 05.2011
ii Contents

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00 – Technical data
1 Brake allocation via PR No.
The type of brake system installed in the vehicle is indicated
among other things by the corresponding PR number on the ve‐
hicle data sticker.
1.1 Example of a vehicle data sticker
In this example the vehicle is equipped with the following brakes:
♦ Arrow 1 - Rear brakes -1KJ
♦ Arrow 2 - Front brakes -1LG
The vehicle data sticker can be found in the spare wheel well and
in the service booklet.
The following table explains the PR numbers. These are impor‐
tant for combining the brake caliper/brake disc/brake drum and
brake pads.
♦ Allocation ⇒ Electronic Parts Catalogue (ETKA) .
1.2 Front brakes
Engine PR No. Front brakes
3.0l - 176 kW TDI 1) 1LC Brembo (17")
3.6l - 206 kW FSI1)
4.2l - 250 kW TDI 1LG Brembo (18")
3.0l - 245 kW TSI, hy‐
brid
1) Only for vehicles with no electric differential lock
Country-specific brake for North America:
Engine PR No. Front brakes
3.0l - 176 kW TDI 1LE Brembo (17")
3.6l - 206 kW FSI
3.0l - 245 kW TSI, hy‐
brid 1LJ Brembo (18")
1.3 Rear brakes
Engine PR No. Rear brakes
3.0l - 176 kW TDI 1KJ Brembo (17")
4.2l - 250 kW TDI
3.0l - 245 kW TSI, hy‐
brid
Country-specific brake for North America:
Engine PR No. Front brakes
3.0l - 176 kW TDI 1KQ Brembo (17")
Touareg 2010 ➤
Brake systems - Edition 05.2011
1. Brake allocation via PR No. 1

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3.0l - 245 kW TSI, hy‐
brid
Touareg 2010 ➤
Brake systems - Edition 05.2011
2 Rep. gr.00 - Technical data

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2 Technical data
2.1 Brake master cylinder and brake servo
Brake master cylinder ∅ in mm 26,99
Brake servo ∅ in inches 9" / 10" - tandem
2.2 Front brakes
2.2.1 Front brake, Brembo (17")
Item PR No. 1LC / 1LE
1 Brake caliper Brembo (17")
2 Brake lining,
thickness mm 10,5
Brake pad, wear
limit without
backplate
mm 2
3 Brake disc ∅ in mm 330
Brake disc,
thickness mm 32
Brake disc,
wear limit mm 30
4 Brake caliper
piston ∅ in mm 4 x 46
2.2.2 Front brake, Brembo (18")
Item PR No. 1LT / 1LU
1 Brake caliper Brembo (18")
2 Brake lining,
thickness mm 10
Brake pad, wear
limit without
backplate
mm 2
3 Brake disc ∅ in mm 368
Brake disc,
thickness mm 36
Brake disc,
wear limit mm 34
4 Brake caliper
piston ∅ in mm 6 x 36
Touareg 2010 ➤
Brake systems - Edition 05.2011
2. Technical data 3

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2.3 Rear brakes
2.3.1 Rear brakes (17" brake disc)
Item PR No. 1KJ / 1KQ
1 Brake caliper Brembo (17")
2 Brake lining,
thickness mm 10
Brake pad, wear
limit without
backplate
mm 2
3 Brake disc ∅ in mm 330
Brake disc,
thickness mm 28
Brake disc,
wear limit mm 26
4 Brake caliper
piston ∅ in mm 4 x 46
2.3.2 Parking brake (17" brake drum)
Item
1 Brake drum ∅ in
mm 210
Brake drum, wear
limit ∅ in mm 211
2 Brake lining,
width mm 30
Brake lining, total
thickness mm 5,5
Brake lining,
wear limit without
backplate
mm 1
Touareg 2010 ➤
Brake systems - Edition 05.2011
4 Rep. gr.00 - Technical data

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3 Brake test
3.1 General
♦ The drive is provided by the roller dynamometer.
♦ For the test ensure for vehicles with a manual gearbox that the
gear lever is in neutral, and for vehicles with an automatic
gearbox that the selector lever is in »N«.
♦ For the test, observe the specifications provided by the man‐
ufacturer of the roller dynamometer.
Note
The brake regulation systems do not function when ignition is off.
3.2 Testing vehicles with no electric differ‐
ential lock
The brake test must be performed on a single-axle roller dyna‐
mometer.
The maximum test speed must not exceed 6 km/h.
The test rigs authorised by Volkswagen fulfil these requirements.
3.3 Testing vehicles with electric differential
lock
The brake test must be performed on a regulated contra-rotating
roller brake test stand.
„Contra-rotating“ means that the dynamometer rollers are driven
forwards on one side and backwards on the other side.
„Regulated“ means that the speed of the brake test stand rollers
is so controlled so that there is no difference in speed during the
brake test.
This prevents the transfer of a force through the stationary wheels
(not on the set of rollers) via the propshaft to the rotating wheels
on the rollers.
The forward rotating wheel is measured during the test, which
means two brake tests per axle must be performed.
The maximum test speed must not exceed 6 km/h.
The test rigs authorised by Volkswagen fulfil these requirements.
3.4 Testing the electromechanical parking
brake
3.4.1 Vehicles with no electric differential lock:
Activate »TÜV mode«:
• Rear axle on single-axle roller dynamometer
• Ignition remains switched on
• Front wheels must be stationary for a minimum of 3 seconds.
• Rear wheels must rotate at constant speed between 2.2 and
12 km/h for at least 3 seconds.
Touareg 2010 ➤
Brake systems - Edition 05.2011
3. Brake test 5

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Entering »TÜV mode« is indicated by the yellow electric parking
brake and handbrake fault warning lamp -K214- lighting up.
End »TÜV mode«:
• Release electromechanical parking brake using electrome‐
chanical parking brake button -E538- .
• Ignition off.
• Selector lever not in »N«.
• Speed of all wheels greater then 2.2 km/h.
Touareg 2010 ➤
Brake systems - Edition 05.2011
6 Rep. gr.00 - Technical data

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45 – Anti-lock brake system
1 General notes for anti-lock brake sys‐
tem (ABS)
On vehicles with ABS Mark 25, only the following version is in‐
stalled:
♦ ABS/EDL/TCS with electronic stabilisation program (ABS/
EDL/TCS/ESP)
The ABS brake system is divided front and rear. The servo-as‐
sistance is effected pneumatically by the vacuum brake servo
unit.
Faults in the ABS influence the brake system and servo assis‐
tance. A change in braking behaviour is to be reckoned with. After
the ABS warning lamp comes on, the rear wheels may lock pre‐
maturely during braking.
Models with ABS Mark 25 do not have a mechanical brake pres‐
sure regulator. Specially matched software in the control unit
regulates the brake force distribution on the rear axle.
The hydraulic unit -2- and control unit -1- form one component.
Separation is possible. Hydraulic pump -3- must not be separated
from hydraulic unit.
New control units from the replacement parts service are not co‐
ded. They must be coded once installed. ⇒ Coding control unit
using VAS 5051 via function "Guided fault finding".
Touareg 2010 ➤
Brake systems - Edition 05.2011
1. General notes for anti-lock brake system (ABS) 7

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2 Notes for repair work on the ABS
♦ Before carrying out repair work on the anti-lock brake system,
determine the cause of the fault using „Guided Fault Finding“.
„Guided fault finding“ is carried out on the vehicle diagnosis, test‐
ing and information system -VAS 5051- .
♦ Before working on the anti-lock brake system, disconnect the
battery earth strap. Note or request radio code on vehicles with
coded radio if necessary.
♦ Before carrying out welding work with an electric welding unit,
note ⇒ General Information; Body Repairs, General Body Re‐
pairs .
♦ When working with brake fluid, observe the relevant safety
precautions and notes ⇒ page 75 .
♦ After work for which the brake system had to be opened, bleed
the brake system with brake filling and bleeding equipment -
VAS 5234- ⇒ page 75 .
♦ During the final road test, ensure that a controlled brake test
is performed at least once (pulsations must be felt at the brake
pedal).
♦ Absolute cleanliness is required when working on the anti-lock
brake system. It is not permitted to use any products which
contain mineral oil, such as oils, greases etc.
♦ Thoroughly clean all unions and the adjacent areas before
loosening. Do not use aggressive cleaning agents such as
brake cleanser, petrol, thinners or similar.
♦ Place removed parts on a clean surface and cover.
♦ If repairs cannot be carried out immediately, carefully cover or
seal open components. ( Sealing plugs -1 H0 698 311 A- must
be used).
♦ Only use lint-free cloths.
♦ Only unpack replacement parts immediately prior to fitting.
♦ Only use genuine packed parts.
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ Ensure that no brake fluid enters connectors.
♦ During painting operations, the electronic control unit can be
exposed to a maximum temperature of 95 °C for only a short
period, and to a maximum of 85 °C for longer periods (approx.
2 hours).
Touareg 2010 ➤
Brake systems - Edition 05.2011
8 Rep. gr.45 - Anti-lock brake system

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3 Connecting -VAS 5051- and select‐
ing functions
Special tools and workshop equipment required
♦ -VAS 5051- Vehicle Diagnosis, Testing and Information Sys‐
tem
♦ Diagnosis cable -VAS 5051/1- or -VAS 5051/3-
WARNING
♦ During a road test, you must always secure testing and
measuring equipment on the back seat.
♦ These devices may be operated only by a passenger while
the vehicle is in motion.
– Connect connector of diagnostic cable -VAS 5051/1- or -
VAS 5051/3- to diagnostic cable -arrow-.
Touareg 2010 ➤
Brake systems - Edition 05.2011
3. Connecting VAS 5051 and selecting functions 9

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– Switch on tester -arrow-.
The tester is ready for operation when the selector buttons for the
operating modes appear on the screen.
– Switch on ignition.
– Touch Guided Fault Finding on screen.
– Select one after another:
♦ Brand
♦ Type
♦ Model year
♦ Body version
♦ Engine code
– Confirm data entered.
Wait until tester has interrogated all control units in vehicle.
– Press Go to and select function „Function/component selec‐
tion“.
– Select „Running gear“ on display.
– Select „Brake systems“ on display.
– Select „01 - Self-diagnosis compatible system…“ shown on
the display.
– Select „Anti-lock brake system…“ shown on the display.
– Select „Function“ shown on display.
Now all possible functions from the anti-lock brake system instal‐
led in the vehicle will be displayed.
– Select desired function on display.
Touareg 2010 ➤
Brake systems - Edition 05.2011
10 Rep. gr.45 - Anti-lock brake system

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4 Electrical/electronic components and locations
1 - ABS control unit -J104-
❑ Location: on hydraulic
unit on right suspension
strut.
❑ Do not separate con‐
nector before success‐
fully completing self-di‐
agnosis. Switch ignition
off before separating
connector.
2 - ABS hydraulic unit -N55-
❑ Location: on right sus‐
pension strut.
The hydraulic unit consists of
the components:
❑ ABS hydraulic pump -
V64-
❑ Valve block (contains in‐
let and outlet valves).
❑ ABS hydraulic pump -
V64- and valve block
must not be separated
from one another.
❑ Brake pressure sender -
G201-
3 - Brake pad warning lamp -
K32-
❑ Location: in dash panel
insert.
4 - ABS warning lamp -K47-
❑ Location: in dash panel
insert.
5 - Brake system warning lamp
-K118-
❑ Location: in dash panel insert.
6 - ESP and TCS warning lamp 2 -K216-
❑ Location: in dash panel insert.
❑ ESP/TCS system has been switched off by the ESP and TCS button -E256- .
7 - ESP and TCS warning lamp -K155-
❑ Location: in dash panel insert.
8 - Brake light switch -F-
❑ Removing and installing ⇒ page 79 .
9 - TCS and ESP button -E256-
❑ Location: in centre console.
10 - Steering angle sender -G85-
❑ Location: on steering column between steering wheel and steering column switch.
❑ Observe installation instructions ⇒ page 27 .
11 - ESP sensor unit -G419-
❑ Location: under centre console.
Touareg 2010 ➤
Brake systems - Edition 05.2011
4. Electrical/electronic components and locations 11

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❑ Combined lateral acceleration sender -G200- , yaw rate sender -G202- and longitudinal acceleration
sender -G251- .
❑ Combined in one housing.
❑ Observe installation instructions ⇒ page 26 .
12 - Diagnostic connection
❑ Location: Driver footwell cover.
❑⇒ page 12
13 - Wheel hub with wheel bearing
❑ ABS sensor ring is installed in wheel bearing.
14 - Front right speed sensor -G45- / front left speed sensor -G47-
❑ Renewing ⇒ page 23 .
15 - Rear right speed sensor -G44- / rear left speed sensor -G46-
❑ Renewing ⇒ page 25 .
16 - Wheel hub with wheel bearing
❑ ABS sensor ring is installed in wheel bearing.
Diagnostic connection
Touareg 2010 ➤
Brake systems - Edition 05.2011
12 Rep. gr.45 - Anti-lock brake system

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5 Assembly overview - hydraulic unit
5.1 ABS MK 25
1 - ABS control unit -J104-
❑ Removing and installing
⇒ page 18 .
2 - ABS hydraulic unit -N55-
❑ Removing and installing
⇒ page 18 .
3 - Torx bolt, 2+0.8 Nm
❑ Without canting, tighten
in stages using diagonal
sequence.
4 - Bracket
❑ Allocation ⇒ Electronic
Parts Catalogue (ET‐
KA) .
5 - Bolt, 9 Nm
6 - Rubber damper
7 - Brake line, 18 Nm
❑ From secondary piston
circuit of brake master
cylinder to hydraulic
unit.
❑ Identification: ∅ 8.5 mm
and union nut with
thread M12 x 1.
8 - Brake line, 18 Nm
❑ From primary piston cir‐
cuit of brake master cyl‐
inder to hydraulic unit.
❑ Identification: ∅ 8.5 mm
and union nut with
thread M12 x 1.
9 - Brake servo and brake mas‐
ter cylinder
❑ Assembly overview ⇒ page 78 .
❑ Removing and installing (LHD) ⇒ page 96
❑ Removing and installing (RHD) ⇒ page 98
10 - Brake line, 14 Nm
❑ To rear left brake caliper.
❑ Identification: ∅ 5.25 mm and union nut with thread M12 x 1.
11 - Brake line, 14 Nm
❑ To front right brake caliper.
❑ Identification: ∅ 5.25 mm and union nut with thread M10 x 1
12 - Brake line, 14 Nm
❑ To front left brake caliper.
❑ Identification: ∅ 5.25 mm and union nut with thread M12 x 1.
Touareg 2010 ➤
Brake systems - Edition 05.2011
5. Assembly overview - hydraulic unit 13

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13 - Brake line, 14 Nm
❑ To rear right brake caliper.
❑ Identification: ∅ 5.25 mm and union nut with thread M10 x 1
Connecting brake lines from brake master cylinder to hydraulic
unit
On brake master cylinder:
On hydraulic unit:
A - From hydraulic unit to primary piston circuit of brake master
cylinder.
- Identification: ∅ 8.5 mm and union nut with thread M12 x 1.
B - From hydraulic unit to secondary piston circuit of brake master
cylinder.
- Identification: ∅ 8.5 mm and union nut with thread M12 x 1.
1 - From hydraulic unit to rear left brake caliper.
- Identification: ∅ 5.25 mm and union nut with thread M12 x 1.
2 - From hydraulic unit to front right brake caliper.
- Identification: ∅ 5.25 mm and union nut with thread M10 x 1
3 - From hydraulic unit to front left brake caliper.
- Identification: ∅ 5.25 mm and union nut with thread M12 x 1.
4 - From hydraulic unit to rear right brake caliper.
- Identification: ∅ 5.25 mm and union nut with thread M10 x 1
5.1.1 Removing and installing control unit
separately
Special tools and workshop equipment required
♦ Torque wrench -V.A.G 1783-
Touareg 2010 ➤
Brake systems - Edition 05.2011
14 Rep. gr.45 - Anti-lock brake system

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Removing:
– Note or request radio code on vehicles with coded radio if
necessary.
– Disconnect battery ⇒ Electrical system; Rep. gr. 27 ; Discon‐
necting and reconnecting battery .
– Remove air intake pipe (not fitted on all engines), release hose
clips -arrows- and pull off hose -1-.
Vehicles with diesel engine:
– Unscrew fuel filter -arrows-, do not disconnect fuel lines, place
fuel filter to side.
– Disconnect connector for air suspension, unscrew securing
bolts -arrows- and remove bracket for fuel filter.
Touareg 2010 ➤
Brake systems - Edition 05.2011
5. Assembly overview - hydraulic unit 15

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Continuation for all vehicles
– Remove bolts -arrows- on coolant expansion tank -1-.
– Slide coolant expansion tank -1- in -direction of arrow- out of
retainer.
– Place coolant expansion tank -1- to one side.
Note
Do not pull off coolant hoses.
– Thoroughly clean control unit, hydraulic unit and surrounding
area.
– Use a vacuum cleaner to vacuum the control unit, the hydraulic
unit and the extended area off to prevent dirt and moisture from
entering the system.
– Release control unit connector -arrow 1- and pull off
-arrow 2-.
– Unscrew control unit -2- and pull it off hydraulic unit -3- without
canting it.
Touareg 2010 ➤
Brake systems - Edition 05.2011
16 Rep. gr.45 - Anti-lock brake system