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9
Chapter 9
Braking system
System type:
Footbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual-circuit hydraulic with servo assistance on all non-basic models.
Anti-lock braking (ABS) optional on certain later models.
Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical by cables to rear brakes
Front brakes
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solid or ventilated disc, with single piston sliding calipers
Brake pad minimum lining thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm
Disc diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247 mm
Disc thickness:
New:
Non-ventilated disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 mm
Ventilated disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.4 mm
Minimum after resurfacing:
Non-ventilated disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 mm
Ventilated disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.9 mm
Maximum disc run out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07 mm
Rear drum brakes
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-adjusting drum with leading and trailing shoes
Brake shoe minimum lining thickness . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 mm
Drum internal diameter:
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180.0 mm
Maximum after resurfacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181.0 mm
Drum out-of-round (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm
Rear disc brakes
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disc, with single piston sliding calipers
Brake pad minimum lining thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 mm
Disc diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247 mm
Disc thickness:
New . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 mm
Minimum after resurfacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0 mm
Maximum disc run out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.07 mm
Anti-lock braking system (ABS) - general information . . . . . . . . . . . . 19
Anti-lock braking system (ABS) components - removal and refitting 20
Brake disc - inspection, removal and refitting . . . . . . . . . . . . . . . . . . 9
Brake fluid level check . . . . . . . . . . . . . . . . . . . . .See
“Weekly checks”
Brake fluid renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Brake pad wear check . . . . . . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Brake pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Front brake caliper - removal, overhaul and refitting . . . . . . . . . . . . . 7
Front brake pads - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Handbrake - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Handbrake cables - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Handbrake lever - removal and refitting . . . . . . . . . . . . . . . . . . . . . . 18
Hydraulic pipes and hoses - renewal . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic system - bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Master cylinder - removal, overhaul and refitting . . . . . . . . . . . . . . . 12
Rear brake caliper (1.9 GTI models) - removal, overhaul
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Rear brake compensator (GTI models) - general information, removal
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Rear brake hub/drum - removal, inspection and refitting . . . . . . . . . 11
Rear brake pads (1.9 GTI models) - renewal . . . . . . . . . . . . . . . . . . . 6
Rear brake shoes - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Rear brake shoe wear check . . . . . . . . . . . . . . . . . . . . . .See Chapter 1
Rear wheel cylinder - removal, overhaul and refitting . . . . . . . . . . . . 10
Underbody and fuel/brake line check . . . . . . . . . . . . . . .See Chapter 1
Vacuum servo unit - testing, removal and refitting . . . . . . . . . . . . . . 14
9•1
Specifications
Contents
Easy, suitable for
novice with little
experience
Fairly easy, suitable
for beginner with
some experience
Fairly difficult,
suitable for competent
DIY mechanic
Difficult, suitable for
experienced DIY
mechanic
Very difficult,
suitable for expert DIY
or professional
Degrees of difficulty
5
4
3
2
1