Contents - Volkspage

Chapter 9
Braking system
Contents
Brake disc - inspection, removal and refitting .................. .6
Brake fluid level check .......................... .See Chapter 1
Brake fluid renewal ............................ .See Chapter 1
Brake pedal - removal, overhaul and refitting ................. .1 1
Brake system and fluid leakage check ............. .See Chapter 1
Front brake caliper - removal, overhaul and refitting ............. .8
Front brake pad check ......................... .See Chapter 1
Front brake pads - renewal ................................ .4
General information ...................................... .1
Handbrake - adjustment .................................. .14
Handbrake cables - removal and refitting .................... .16
Handbrake lever - removal and refitting ...................... .15
Handbrake “on” warning light switch - removal and refitting ...... .I9
Degrees of difficulty
Hydraulic system - bleeding ................................ .2
Hydraulic pipes and hoses - renewal ......................... .3
Master cylinder - removal, overhaul and refitting ............... .10
Rear brake drum - removal, inspection and refitting ............. .7
Rear brake pressure-regulating valve - removal, refitting and
adjustment.............................................17
Rear brake shoe and drum check ................. .See Chapter 1
Rear brake shoes - renewal ................................ 5
Rear wheel cylinder - removal, overhaul and refitting ............ .9
Stop-light switch - removal and refitting ..................... .18
Vacuum servo unit non-return valve - removal, testing and refitting .13
Vacuum servo unit - testing, removal and refitting .............. .12
Specifications
Front brakes
Disc type:
VW1 (except G40 Coupe models) . . . . . . . . . . . . . . . . . . . . . . . . . . .
VW2 (G40 Coupe models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disc diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disc thickness (new):
WV1 (except G40 Coupe models) . . . . . . . . . . . . . . . . . . . . . . . . . . ,
VW2 (G40 Coupe models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disc thickness (minimum):
WV1 (except G40 Coupe models) . . . . . . . . . . . . . . . . . . . . . . . . . . .
VW2 (G40 Coupe models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum disc runout . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . .
Brake pad thickness including backing (new):
VW (except G40 Coupe models) . . . . . . . . . . . . . . . . . . . . . . . . . . .
VW2 (G40 Coupe models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake pad thickness including backing (minimum):
VW1 (except G40 Coupe models) . . . . . . . . . . . . . . . . . . . . . . . . . . .
VW2 (G40 Coupe models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard
Ventilated
239 mm
10mm
20 mm
8mm
18mm
0.06 mm
12.0 mm
10.0 mm
7.0 mm
5.0 mm
Rear drum brakes
Drum diameter:
New ................................................. 180 mm
Maximum diameter ....................................... 181 mm
Maximum drum out-of-round ................................. 0.05 mm
Brake shoe friction material thickness (minimum) ................. 2.5 mm
Torque wrench settings
Nm
Brake servo mounting bracket to servo ......................... 20
Master cylinder ............................................ 20
Servo mounting bracket ..................................... 15
Front brake caliper to fixed member ........................... 25
Front brake caliper fixed member to bearing housing .............. 70
Front brake backplate ....................................... 10
Handbrake lever ........................................... 20
Rear brake backplate ....................................... 60
Ibf ft
15
15
11
19
52
7
15
44