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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Volkswagen Touareg (from 2003 to 2006, the year of issue)

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Volkswagen Touareg
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Volkswagen
Touareg
Operation and maintenance of car
Engine
Transmission
Chassis
Steering Gear
Brakes
Overview
Example data plate car
Front brakes
Rear brakes
Check the brake system
Bleeding brake system
Bleeding (major)
Additional pumping
The sequence of pumping
Removal and installation of the membrane potentiometer stroke brake booster G420
Removal and installation of the vacuum pump the brakes V192
Removing and installing brake servo pressure sensor G294
Removal and installation of the main brake cylinder
Removing and installing brake booster
Repair the brake pipe
Repairing front brake, Brembo brake calipers 17 '' (1LC)
Removing and installing brake pads
Repair rear wheel brakes, brake caliper FN 44
Removing and installing brake pads
Adjusting the parking brake
Adjust the brake pads on two wheels
Checking freewheel lever parking brake pedal
Removal and installation of the lever of the foot parking brake
Removing and installing rear brake cables
Disconnecting the brake pedal from the brake booster
Connecting the brake pedal to the brake booster
Removal, installation and adjustment of brake light switch
Anti-lock braking system (ABS)
Tables
Onboard electric
Body
diagrams
 


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Anti-lock braking system (ABS)



Brake system with ABS and a dual-diagonal. Amplification is performed in a brake system with a vacuum booster.
Faults affect ABS braking system and strengthening it. In the case of an ABS fault should be regarded as a change in the braking force. After ignition control lamp ABS rear wheels during braking can lock up prematurely.
Vehicles with ABS Mark 25 is not equipped with a mechanical brake-power. Special software in the control unit monitors the distribution of braking force to the rear axle.

ABS control unit
Fig. 6.61. ABS control unit


The control unit 1 and unit 2 of hydraulics form a single unit (Fig. 6.61).
The separation is only possible in the removed condition. The hydraulic pump 3 can not be disconnected from the power hydraulics.
New control units as spare parts are not coding. After installation you need to code them.

Electrical / electronic components

Electrical / electronic components
Fig. 6.62. Electrical / electronic components: 1 - Hydraulic unit ABS; 2 - Control unit ABS; 3 - pressure sensor brake system; 4 - pressure sensor gain in the brake system; 5 - the vacuum pump the brakes; 6 - a control lamp ESP and ASR; 7 - control lamp ABS; 8 - a control lamp of brake system; 9 - key systems, ASR and ESP; 10 - sensor unit ESP; 11 - the gauge of the steering angle; 12 - diagnostic connector; 13 - brake light switch and the brake pedal sensor; 14 - front right speed sensor / front left speed sensor; 15 - wheel bearing / wheel hub assembly; 16 - rear right speed sensor / rear left speed sensor; 17 - wheel bearing / wheel hub assembly


Electrical / electronic components of the ABS system is shown in Fig. 6.62.

Fault warning lights
If the ABS warning lamp 3 does not go out after the ignition and complete control cycle, the causes of failure can be as follows:
- Voltages of less than 10;
- There is a malfunction ABS.


When a defect ABS b-lock braking system is deactivated, the brake system itself remains in working condition;

Diagnostic connector
Fig. 6.63. Diagnostic connector



- After the last start of the engine there was a temporary glitch speed sensor.
In this case, the ABS warning lamp turns off automatically when you restart the engine and then a speed above 2.75 km / h;
- Broken connection from the instrument cluster to the control unit ABS;
- Faulty control lamp ABS.

Warning lights
Fig. 6.64. Warning lights



ABS warning lamp and control lamp of brake system
If the ABS warning lamp goes out and control lamp of brake lights, the cause of the fault can be as follows:
- Brake fluid level is too low.
When the ignition is heard three alarms.
- The wiring to the brake system warning lamp K118
If you burn the ABS warning lamp 3 and the brake system warning lamp 4 - faulty ABS. In the case of an ABS fault should be regarded as a change in the braking force.

ATTENTION
After ignition control lamp ABS warning lamp and brake the rear wheels can lock early when braking.

ESP warning lamp and ASR
If the ESP warning lamp and ASR does not go out after the ignition is switched on and complete control cycle, the causes of failure can be as follows:
- There is a problem that concerns only the ASR / ESP. Vehicle Safety Systems ABS / EDS and EBV remain fully operational. Interrogate fault memory;
- Short to positive in the button ASR / ESP;
- Short to ground control control lamp ESP and ASR;
- Interrupted connection from the dash to the contact 31 of the control unit ABS;
- The system ASR / ESP button has been disabled ASR / ESP.
If the ESP warning lamp and ASR flashes during driving, the ASR system or ESP are in control.

Brake System Warning Light
If the control lamp of brake system after the ignition is not extinguished, then it may have the following reasons:
- Parking brake is applied;
- The switch of a control lamp of brake system is defective or incorrectly adjusted;
- There is an error in the wiring. Perform electrical check.
Contact the parking brake switch ABS control unit transmits information that is involved or not the parking brake. When the parking brake to regulate the ESP is a negative impact.

Control lamp of brake pad wear
If the warning light brake wear does not go out after 3 sposle ignition is switched on or comes on while driving, the cause of this problem may include the following:
- Brake linings may be worn.
Check brake pads front and rear wheels. Replace the pads if they are worn out;
- There is a fault in the wiring.

Removal and installation of components of the ABS system on front and rear axles

Components of ABS on the front axle
Fig. 6.65. Components of ABS on the front axle: 1 - speed sensor ABS; 2 - a bolt with hexagon socket, 8 Nm; 3 - wheel hub bearing (bearing assembly); 4 - drive shaft


Components of ABS on the front axle are shown in Fig. 6.65.
Removing and installing speed sensor on the front axle
Raise the vehicle.

Connector
Fig. 6.66. Connector


Disconnect connector 1 cable speed sensor and speed sensor (Fig. 6.66).
Remove the bolt 2 from the wheel bearing housing.
Remove ABS speed sensor from wheel bearing housing.

Setting
Before installing the speed sensor, clean the hole and apply a little grease on the entire diameter
Insert the speed sensor into the hole wheel bearing housing and tighten bolt to 8 Nm.
Connect the speed sensor to the sensor cable.
Removal and installation of components of system ABS on the rear axle

Components of ABS on the rear axle
Fig. 6.67. Components of ABS on the rear axle: 1 - speed sensor ABS; 2 - a bolt with hexagon socket, 8 Nm; 3 - wheel bearing / wheel hub assembly; 4 - drive shaft


Components of ABS rear axle are presented in Fig. 6.67.

Removing and installing speed sensor on the rear axle
Raise the vehicle.

Connector
Fig. 6.68. Connector


Disconnect connector 1 cable speed sensor and speed sensor (Fig. 6.68).
Remove the bolt 2 from the wheel bearing housing.
Remove ABS speed sensor from wheel bearing housing.
Before installing the speed sensor, clean the hole and apply a little grease on the entire diameter
Insert the speed sensor into the hole wheel bearing housing and tighten bolt to 8 Nm.
Connect the speed sensor to the sensor cable.




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