1991 Volkswagen Jetta Brake Service (ONLINE REPAIR MANUALS)

EXCEPT CORRADO w/ELECTRONIC DIFFERENTIAL LOCK (EDL)

The ABS control unit has a permanent fault memory. If problems occur at electrically monitored sensors or components they are stored in memory.

Faults are stored with varying priorities, solenoid faults have the highest priority and are displayed first. Faults which occur occasionally, or sporadic faults have the lowest priority and are displayed last.

VAG 1551 Diagnostic Tester, Connecting

Do not drive vehicle with VAG 1551 diagnostic tester connected.

• Ensure fuses S16, S53 and S54 are in satisfactory condition, turn i...

• Place caliper so that piston bore is facing down.
• Open bleeder valve, then connect a ...

PARKING BRAKE

CORRADO & PASSAT

• Ensure parking brake lever is in OFF position, then tighten adjusting nut until levers on calipers just move off their stops. Maximum permissible distance from stop is.059 inch.
• Apply and release parking brake and ensure that both wheels rotate freely.

EXCEPT CORRADO & PASSAT

• Release parking brake handle and ensure that levers on calipers return to stop.
• Loosen cab...

MODELS LESS ANTI-LOCK BRAKES

Fox

To bleed brake system, use bottle with a transparent hose attached so that brake fluid can be checked for air bubbles.

• Ensure that engine is Off, then disconnect vacuum hose/check valve from brake booster.
• Push lever on brake pressure regulator in direction of rear axle.
• On all models, bleed brakes in following sequence:
• Right rear wheel cylinder, left rear wheel cylinder, right front caliper, then left front caliper.
• After bleeding, fill reservoir to maximum mark.
• Reconnect vacuum hose/check valve to brake booster.

Except Fox

To bleed brake system, use bot...

• Raise and support vehicle, then remove rear wheels.
• Disconnect parking cables from caliper.
• On Corrado and Passat models, remove mounting bolts, then the caliper.
• On GTI 16V, Jetta Carat & Jetta GLI 16V,remove upper mounting bolt, then swing caliper downward.
• Remove brake pads.
• On Corrado and Passat models, screw piston into housing using caliper tool 3131 or equivalent by turning clockwise while pushing in firmly. Always remove some brake fluid from master cylinder reservoir prior to installing new pads. When caliper piston is pushed back, fluid is forced out of caliper and into r...

Prior to servicing the ABS system, always turn the ignition off, disconnect battery negative cable, and reduce pressure in the reservoir by pressing the brake pedal at least 25-35 times. The reduction in pressure can be felt when pedal effort increases. Serious injury may result if the system is serviced without reducing pressure.

The ABS control unit must never be exposed to temperatures greater than 185°F for more than two hours, or 203°F for even short time periods. The ABS control unit must be unplugged if an electric welder is to be used on the vehicle. ...