0% found this document useful (0 votes)

28 views194 pages

S01DAXX8U20 Brake System

Uploaded by

carleaderengine

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

0% found this document useful (0 votes)

28 views194 pages

S01DAXX8U20 Brake System

Uploaded by

carleaderengine

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

You are on page 1/ 194

Service

Workshop Manual
Altea 2004 ➤ , Altea 2009 ➤ ,
Altea XL 2007 ➤ , Altea XL 2009 ➤ ,
Altea XL Freetrack 2008 ➤ ,
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

Altea XL Freetrack 2009 ➤ ,

permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

León 2006 ➤ , León 2009 ➤ ,

Toledo 2005 ➤ , Toledo 2009 ➤
Brake system
Edition 03.2015

Service Department. Technical Information

Service
List 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.

All rights reserved.

No reproduction without prior agreement from publisher.

Copyright © 2015 Seat S.A S01DAXX8U20

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Assignment PR Number/Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Brake specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 Brake test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.2 Vehicles with front-wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Vehicles with four wheel drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

1 General notes on anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.1 Indications regarding repairs to the ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2 Connecting the vehicle diagnosis device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Electrical/electronic components and locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1 ABS Mark 70 -ABS/ASR- (until week 22.08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 ABS Mark 70 -ABS/ASR/EBV/RKA- (after week 22.08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 ABS Mark 60 -ABS/EDS/ASR/ESP- (until week 22.08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.4 ABS Mark 60 -ABS/EDS/ASR/ESP/RKA+/EBA/DSR - HHC (from week 22.08) - XDS 1 2 -
NBA 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 Viewing the faults indicated by the control warning lamps . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.1 Warning lamp in the dash panel insert up to week 12.2009 . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 Warning lamp in the dash panel insert from week 12.2009 . . . . . . . . . . . . . . . . . . . . . . . . 24
5 ABS/ESP system components: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.1 Brake light switch F and Brake pedal position sender G100 : installation and removal . . . . 28
5.2 ESP sensor unit G419 :removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.3 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.4 Braking pressure sender -1- G201 : removing and installing . . . . . . . . . . . . . . . . . . . . . . . . 32
5.5 Vacuum transmitter of the brake servo G483 : installation and removal . . . . . . . . . . . . . . 33
6 Hydraulic unit, brake servo/brake master cylinder: Assembly overview . . . . . . . . . . . . . . . . 35
6.1 ABS Mark 70 -ABS/ASR- (until week 22.08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.2 ABS Mark 70 -ABS/ASR/EBV/RKA- (after week 22.08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.3 ABS Mark 60 -ABS/EDS/ASR/ESP- (until week 22.08) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.4 ABS Mark 60 -ABS/EDS/ASR/ESP/RKA+/EBA/DSR- (from week 22.08) . . . . . . . . . . . . . . 56
7 ABS components on the front axle: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.1 Removing and installing speed sensor on front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8 ABS system components in rear axle: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8.1 ABS components on the rear axle (front-wheel drive): Assembly overview . . . . . . . . . . . . 65
8.2 ABS components on S.A.
theSEAT
rearS.Aaxle (4-wheel drive): Assembly
liability with overview . . . . . . . . . . . . . . 66
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT does not guarantee or accept any
respect to the correctness of information in this document. Copyright by SEAT S.A.
46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1 Front wheel brake: repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.1 FS 3 front wheel brake: component overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1.2 FS 3 front wheel brake: brake pads installation and removal . . . . . . . . . . . . . . . . . . . . . . . . 71
1.3 FS 3 front wheel brake: brake calliper installation and removal . . . . . . . . . . . . . . . . . . . . . . 74
1.4 Front brakes FN 3: component overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
1.5 Front brakes FN 3: brake pads installation and removal . . . . . . . . . . . . . . . . . . . . . . . . . . 78
1.6 Front brakes FN 3: Brake calliper installation and removal . . . . . . . . . . . . . . . . . . . . . . . . 82
1.7 FNR G Front wheel brake (Model Leon 2006 Cupra): Assembly overview . . . . . . . . . . . . 84
1.8 FNR-G Front wheel brake (Leon 2006 Cupra model): Brake pads installation and removal
........................................................................ 87

Contents i
Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

1.9 FNR-G Front wheel brake (Leon 2006 Cupra model): Brake calliper installation and
removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.10 FNR G Front wheel brake (Model Leon 2009 Cupra and Cupra R): Assembly overview . . 93
1.11 FNR G Front wheel brake (Model Leon 2009 Cupra and Cupra R): Brake pad installation and
removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
1.12 FNR G Front wheel brake (Model Leon 2009 Cupra and Cupra R): Brake calliper installation
and removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
1.13 Brembo front wheel brake: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
1.14 Brembo rear brake: brake pads installation and removal . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2 Rear wheel brake: repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2.1 CI 38 rear brake: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2.2 CI 38 brake blocks: removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2.3 CI 38 brake caliper: removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.4 CII 38 HR rear brake: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.5 CII 38 HR brake blocks: removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.6 CII 38 HR brake calipers: removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.7 CII 41 HR TRW rear axle brake: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.8 CII 41 HR TRW brake pads: removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2.9 CII 41 HR TRW brake caliper: removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . 124
2.10 ZOH 38 BIR III Bosch rear axle brake: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . 126
2.11 ZOH 38 BIR III Bosch brake pads: removal and installation . . . . . . . . . . . . . . . . . . . . . . . . 127
2.12 ZOH 38 BIR III Bosch brake calipers: removal and installation . . . . . . . . . . . . . . . . . . . . . . 130
3 Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3.1 Parking brake: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3.2 Hand brake cable: removing and installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3.3 Adjust handbrake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
3.4 Handbrake control switch F9 : replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4 Brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.1 Brake pedal, vehicles with the steering wheel on the left - assembly overview . . . . . . . . . . 138
4.2 Brake pedal, vehicles with the steering wheel on the left (automatic gearbox) - assembly
overview permitted
. .Protected
. . . .unless
.by. copyright.
. authorised
. . . . .Copying
.by. SEAT
. . for
. .S.A.
. . SEAT
. . . S.A
. . .does
. . not
. . guarantee
. . . . . .or.accept
. . . .any
. .liability
. . . .with
private or commercial purposes, in part or in whole, is not
............... 139
4.3 Removing and installing
respect to the brake
correctnesspedal . . . in
of information . .this
. .document.
. . . . . .Copyright
. . . . .by. SEAT
. . . .S.A.
................... 140
4.4 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

1 High and low pressure testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
1.1 High pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
1.2 Low-pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
2 Front brake calliper: repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
2.1 FS 3 brake calliper: Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
2.2 Brake caliper FN 3: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
2.3 FNR G brake calliper (Model Leon 2006 Cupra): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
2.4 Removing and installing pistons for front brake calliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
2.5 FNR G brake calliper (Model Leon 2009 Cupra and Cupra R): Assembly overview . . . . . . 149
2.6 Piston for FNR-G brake calliper (Leon 2009 Cupra and Cupra R model): removal and
installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3 Rear brake caliper: repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
3.1 Rear brake calliper: assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
3.2 Piston for rear brake caliper: removing and fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
3.3 Rear brake calliper ZOH 38 BIR III Bosch: assembly overview . . . . . . . . . . . . . . . . . . . . . . 158
3.4 Piston for back brake calliper ZOH 38 BIR III Bosch: installation and removal . . . . . . . . . . 160
4 Bleeding brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.1 Initial purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
4.2 Bleeding the brake system with the brake bleeder SAT 1175B . . . . . . . . . . . . . . . . . . . . 165
4.3 Bleeding the brake system without the brake bleeder SAT 1175B . . . . . . . . . . . . . . . . . . 167
4.4 Specified torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

ii Contents
Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

4.5 Replace brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

5 Brake servo and brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
5.1 Brake servo/brake master cylinder, LL: Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . 169
5.2 Brake servo/brake master cylinder, RL: Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . 171
5.3 Vacuum pump for brake servo: removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . 173
5.4 Checking non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.5 Removing and installing vacuum pump for brakes V192 . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.6 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
5.7 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
6 Brake pipes and brake hoses: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
6.1 Removing and installing brake lines and brake hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
7 Brake pipe repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
7.1 Flaring tool: assembly survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
7.2 Work instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Contents iii
Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

iv Contents
Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

00 – Technical data
1 Technical data
(ERL002689; Edition 03.2015)
⇒ “1.1 Assignment PR Number/Brakes”, page 1
⇒ “1.2 Brake specifications”, page 3

1.1 Assignment PR Number/Brakes

The PR number is used to find the correct combination of brake
calliper/brake disk/brake pad. ⇒ Parts catalogue

1.1.1 Assignment PR Number / Brakes, Altea

2004
PR No. Front brakes, Altea 2004
1ZF FS 3
1ZE FN 3
1LJ FN 3

PR No. Rear brakes, Altea 2004

1KQ CI 38
1KD CI 38
1KZ CII 38 HR

1.1.2 Assignment PR Number / Brakes, Altea

2009
PR No. Front brakes, Altea 2009
1ZF FS 3
1ZE FN 3
1ZA FN 3

PR No. Rear brakes, Altea 2009

1KD CI 38
1KZ CII 38 HR

1.1.3 Assignment PR Number / Brakes, Altea

XL 2007
PR No. Front brakes, Altea XL 2007
1ZF FS 3
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
1ZE permitted unless authorised by SEAT S.A.FNSEAT
3 S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
1LJ FN 3

PR No. Rear brakes, Altea XL 2007

1KD CI 38
1KZ CII 38 HR

1. Technical data 1
Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

1.1.4 Assignment PR Number / Brakes, Altea

XL 2009
PR No. Front brakes, Altea XL 2009
1ZF FS 3
1ZE FN 3
1ZA FN 3

PR No. Rear brakes, Altea XL Rear brakes, Altea XL

2009 4x4 2009
1KD CI 38 -
1KZ CII 38 HR -
1KF - CII 41 HR TRW
1KS - ZOH 38 BIR III Bosch

1.1.5 Assignment PR Number / Brakes, Altea

XL Freetrack 2008
PR No. Front brakes, Altea XL Freetrack 2008
1ZE FN 3
1LJ FN 3

PR No. Rear brakes, Altea XL Freetrack 2008

1KD CI 38
1KJ. CII 41 HR TRW
1KZ CII 38 HR
1KF CII 41 HR TRW

1.1.6 Assignment PR Number / Brakes, Altea

PR No. Front brakes, Altea XL Freetrack 2009

1ZA FN 3

PR No. Rear brakes, Altea XL Freetrack 2009

1KD CI 38
1KJ. CII 41 HR TRW
1KZ CII 38 HR
1KF CII 41 HR TRW
1KS ZOH 38 BIR III Bosch

1.1.7 Assignment PR Number / Brakes, Leon

2006
PR No. Front brakes, Leon 2006
1ZF FS 3
1ZC FS 3
1ZM FS 3
1ZE FN 3
1LJ FN 3
1LU FNR-G
1LT Brembo P4 – 38/42

2 Rep. gr.00 - Technical data

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

PR No. Rear brakes, Leon 2006

1KD CI 38
1KZ CII 38 HR
1KY CII 38 HR

1.1.8 Assignment PR Number / Brakes, Leon

2009
PR No. Front brakes, Leon 2009
1ZF FS 3
1ZE FN 3
1ZA FN 3
1ZB (China) FN 3
1LU FNR-G
1LB FNR-G

PR No. Rear brakes, Leon 2009

1KD CI 38
1KZ CII 38 HR
1KY
Protected by copyright. Copying for privateCII 38 HR purposes, in part or in whole, is not
or commercial
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
1KS respect to the correctness ofZOH 38 BIR
information III Bosch
in this document. Copyright by SEAT S.A.

1KT (China) ZOH 38 BIR III Bosch

1.1.9 Assignment PR Number / Brakes, Tole‐

do 2005
PR No. Front brakes, Toledo 2005
1ZF FS 3
1ZE FN 3
1LJ FN 3

PR No. Rear brakes, Toledo 2005

1KD CI 38
1KZ CII 38 HR

1.1.10 Assignment PR Number / Brakes, Tole‐

do 2009
PR No. Front brakes, Toledo 2009
1ZF FS 3
1ZE FN 3
1ZA FN 3

PR No. Rear brakes, Toledo 2009

1KD CI 38
1KZ CII 38 HR

1.2 Brake specifications

Brake system
ABS system, diagonal double circuit brakes with electronic braking force distribution (EBV). Depending on
the equipment or depending on the version, there may be an electronic differential lock system (EDS), anti-
skid regulation (ASR), electronic stabilization program (ESP)

1. Technical data 3
Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

Brake system
Brake master cylinder ∅ mm 22.2
Brake servo ∅ in inches Vehicles with the steering wheel on the left: 10
functioning pneumatic
Transmission ratio i= 5

Front brake
No. PR of 1ZF 1ZC 1ZM 1ZE 1LJ 1ZA 1ZB 1LU 1LB 1LT
the brake (China)
calliper
Front brake FS3 FS3 FS3 FN3 FN3 FN3 FN3 FNR- FNR- P4-38
calliper G G /42
Piston ∅ mm 54 54 54 54 54 54 54 57 57 38/42
No. PR of 1ZF 1ZC 1ZC 1ZE 1LJ 1ZA 1ZB 1LU 1LB 1LT
the brake
disc
Front brake ∅ mm 280 280 280 288 312 312 312 345 345 345
disk
Brake disk mm 22 22 22 25 25 25 25 30 30 30
thickness,
with interior
ventilation
Brake disc mm 19 19 19 22 22 22 22 27 27 28
wear limit
Brake pad
Thickness mm 14 14 14 14 14 14 14 14 14 -
of the new
trimming
(without the
back plate)
Trimming mm 2 2 2 2 2 2 2 2 2 -
wear limit
(without the
back plate)

Rear brakes
No. PR of the 1KQ 1KD 1KZ 1KY 1KF 1KJ. 1KS 1KT
brake calliper (China)
Rear brake cal‐ CI 38 CI 38 CII 38 CII 38 CII 41 CII 41 ZOH ZOH
liper HR HR HR HR 38 BIR 38 BIR
TRW
Protected by copyright. Copying for private TRWpurposes,IIIin part or in III
or commercial whole, is not
Bosch
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee Bosch
or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Piston ∅ mm 38 38 38 38 41 41 38 38
Brake disc
Rear brake disc ∅ mm 255 255 286 286 260 286 272 272
Brake disk thick‐ mm 10 10 12 12 12 12 10 10
ness, without
ventilation
Brake disk thick‐ mm - - - - - - - -
ness, with interi‐
or ventilation
Brake disc wear mm 8 8 10 10 10 10 8 8
limit
Brake pad

4 Rep. gr.00 - Technical data

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

Rear brakes
Thickness of the mm 12 12 12 12 12 12 12 12
new trimming
(without the
back plate)
Trimming wear mm 2 2 2 2 2 2 2 2
limit (without the
back plate)

1. Technical data 5
Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

2 Brake test
⇒ “2.1 General”, page 6
⇒ “2.2 Vehicles with front-wheel drive”, page 6
⇒ “2.3 Vehicles with four wheel drive”, page 6

2.1 General
The wheels are operated by a test platform.
For the test, manual gear vehicles put the gears in neutral, and
automatic vehicles select N.
For the test, take note of the test platform manufacturer specifi‐
cations.

2.2 Vehicles with front-wheel Protected

driveby copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

2.2.1 Testing the brakes on a single axle test

platform
We recommend using a test platform with a roller speed control
and a maximum test speed of 5 km/h.
If these specifications are not respected there may be reactions
from the braking systems (EDS regulation).
In this case the engine must be stopped and the ignition turned
off for the test. If necessary, run the engine briefly in order to build
up enough pressure for brake operation.

2.3 Vehicles with four wheel drive

2.3.1 Testing the brakes on a single axle test

platform that are rotating in the opposite
direction
In opposite directions means that the rollers of one of the sides
turns forwards while the rollers on the other side turn backwards.
This prevents the braking forces from being transmitted to the
engine unit.
With brake tests, the measurement is always carried out on the
wheel rotating in the driving direction. This is why two brake tests
have to be carried out per axle.
The test speed must not exceed 6 km/h
The roller platforms authorised by SEAT shall meet the following
requirements.

2.3.2 In the event that a test platform for four-

wheel drive vehicles is not available, a
standard single axle roller platform may
be used as follows:
– Raise vehicle onto rollers by driving forwards.
– Switch off engine and wait for 2 seconds.
– Run braking test for front wheels.

6 Rep. gr.00 - Technical data

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Start engine and wait 5 seconds until an adequate vacuum has

been generated.
– Move vehicle forwards until the rear wheels are on the rollers.
– Switch off engine and wait for 2 seconds.
– Run braking test for rear wheels.
– Start engine and wait 5 seconds until an adequate vacuum has
been generated.

2. Brake test 7
Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

3 Brake fluid
⇒ “3.1 General”, page 8

3.1 General

3.1.1 The brake fluid is hygroscopic, that is, it

has a tendency to absorb humidity and
water from the air.
The boiling point decreases as the water content increases, which
means a considerable rise in brake fluid temperature can lead to
formation of vapour bubbles and brake failure.
The colour of the brake fluid becomes darker over the course of
time. At the same time, a dark-coloured liquid must not mean that
the quality is bad. The change in colour is due to chemical reac‐
tions and may happen after a short time (weeks), especially in the
case of vehicles with ABS.

WARNING

The rubber parts of the braking system (sleeves, seals) are not
compatible with mineral oil, petrol or cleaning products.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Contact between such substances and a seal or sleeve, including
respect to the correctness of information in this document. Copyright by SEAT S.A.

in small quantities, will cause modifications to these parts and

could negatively affect brake operation. The consequences of a
contaminated brake system may only become apparent after
some months, however this could imply considerable costs,
above all for vehicles with ABS.

A = sleeve - original size

B = Brake hose - swollen due to contact with mineral oil

3.1.2 Summary of the above mentioned

points:
Ensure that the brake fluid containers are always completely
sealed. This is the only way to ensure that oil, dirt, cleaning prod‐
ucts and humidity do not enter.
Store the brake fluid containers separately from oil containers
(including hydraulic oils) and cleaning products, in order to avoid
any possible mixing or filling error.

8 Rep. gr.00 - Technical data

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

45 – Anti-lock brake system

1 General notes on anti-lock brake sys‐
tem
⇒ “1.1 Indications regarding repairs to the ABS”, page 9

1.1 Indications regarding repairs to the ABS

WARNING

Basically, the antilock braking system does not require main‐

tenance.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Inspections,
respectfitting and repairs
to the correctness mustinonly
of information be carried
this document. out
Copyright by by per‐
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
SEAT S.A.
sonnel specialized in these systems.
If the indications described in the Repair Manual are not re‐
spected, damage may occur in the braking system and vehicle
safety may be affected.

ABS: Diagonal distribution system, double circuit hydraulic brake

with electronic differential lock. The vacuum servo brake pneu‐
matically increases the braking force.
The mechanical braking force distribution for vehicles with the
Mark 60 ABS has been replaced by a software in the control unit,
especially designed to determine the braking forces between
axles.
Faults in the ABS system do not affect the conventional brake
system or the servo brake. The conventional brake system re‐
mains functional even without ABS. However, a change in braking
behaviour must be reckoned with. When the ABS indicator is lit,
using the brakes could cause the rear wheels to lock up before
expected.
♦ Before making repairs to the antilock braking system, locate
the problem using the self-diagnosis.
♦ Release the connector from the hydraulic unit only when the
engine ignition is out of service.
♦ If a new hydraulic control unit is fitted then it must be program‐
med ⇒ Vehicle diagnostic tester.
♦ The hydraulic braking system must be purged of air after being
manipulated. For systems with ABS/ESP Mark 60: The bleed‐
ing of air from the system - SAT 1175B- must be done with the
brake bleeder ⇒ page 163 .
♦ Always strictly follow the relevant safety measures and in‐
structions when handling the brake liquid.
♦ Work on the ABS system demands the highest levels of clean‐
liness; under no circumstances should auxiliary materials that
contain mineral oils such as oil, grease etc. be used
♦ Make sure that brake fluid does not enter the connectors.
♦ Before soldering electronic connections they should be thor‐
oughly cleaned, but do not use strong abrasive cleaning prod‐
ucts such as brake cleaner, petrol, solvents or similar
products.
♦ When the repair work is not carried out immediately, protect
the parts with care and keep them covered. Use the plugs of

1. General notes on anti-lock brake system 9

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

the repair set for this purpose, part number ⇒ Spare parts
catalogue .
♦ Place removed parts on a clean surface.
♦ When the brake system is open, the vicinity of the location
should not be cleaned using compressed air. As a safety
measure, do not move the vehicle.
♦ Only use lint-free cloths.
♦ Only use parts from their original packaging.
♦ Only remove new parts from their packaging immediately be‐
fore fitting.
♦ When carrying out varnishing work: due to safety reasons the
control unit may not be set at a temperature of above 85° for
more than 2 hours.
♦ Before using electric welding equipment, note the relevant
safety measures and indications according to ⇒ Body Repairs;
Rep. gr. 00 ; collective protection .

10 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

2 Connecting the vehicle diagnosis de‐

vice

WARNING

During the test drive, the testing and measuring equipment

must always be fastened to the back seat.
When driving, only the passengers can handle this equipment,
never the driver.

– Handbrake applied.
– Automatic gearbox: set the selector lever in the position “P” or
“N”.
– Manual gearbox: gear lever at neutral.
With the ignition switched off, connect the vehicle diagnosis tester
in the following manner:
Leon 2006►
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

– Remove the cover -1- under the steering

Copyrightcolumn from the side
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. by SEAT S.A.
-arrows-.
Altea 2004►, Altea XL 2007►, Altea XL Freetrack 2008► and Tol‐
edo 2005►

– Remove cover -1- located below steering column.

Continues for all models

– Connect the vehicle diagnosis device -arrow- with the cable

provided.
– Select the desired function on the screen ⇒ Vehicle diagnostic
tester.

2. Connecting the vehicle diagnosis device 11

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

3 Electrical/electronic components and

locations
⇒ “3.1 ABS Mark 70 -ABS/ASR- (until week 22.08)”, page 12
⇒ “3.2 ABS Mark 70 -ABS/ASR/EBV/RKA- (after week 22.08)”,
page 14
⇒ “3.3 ABS Mark 60 -ABS/EDS/ASR/ESP- (until week 22.08)”,
page 16
⇒ “3.4 ABS Mark 60 -ABS/EDS/ASR/ESP/RKA+/EBA/DSR -
HHC (from week 22.08) - XDS 1 2 - NBA 3 ”, page 18

3.1 ABS Mark 70 -ABS/ASR- (until week 22.08)

1 - ABS control unit - J104-

❑ Assembly location: in
the hydraulic control
unit, in the engine com‐
partment, to the right
❑ Can be checked in “Gui‐
ded Fault Finding” diag‐
nostic tester
❑ Do not separate con‐
nector before success‐
fully completing self-di‐
agnosis. Switch ignition
off before separating
connector.
❑ Removing and installing
⇒ page 37
2 - Hydraulic units for the ABS.
- N55-
❑ Fitting location: in en‐
gine compartment
(right-side)
The hydraulic unit consists of
the following components:
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ ABS hydraulic
respect pump
to the correctness -
of information in this document. Copyright by SEAT S.A.
V64-
❑ Can be checked in “Gui‐
ded Fault Finding” diag‐
nostic tester
❑ Valve block (contains in‐
let and outlet valves).
❑ The ABS hydraulic
pump - V64- must not be
separated from the
valve block.
❑ Removing and installing
⇒ page 37
3 - Brake system indicator - K118-
❑ Location: in dash panel insert.
❑ Brake malfunction, handbrake
❑ If flashing, check the brake fluid level
❑ Function: ⇒ page 21

12 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

4 - ABS warning lamp - K47-

❑ Location: in dash panel insert.
❑ Function: ⇒ page 21
5 - Traction control system warning lamp - K86-
❑ Location: in dash panel insert.
❑ Function: ⇒ page 21
6 - Brake pad warning lamp - K32-
❑ Location: in dash panel insert.
❑ Function: ⇒ page 21
7 - Brake light switch - F- and brake pedal switch - F47-
❑ In vehicles prior to week 45/05
❑ Location: on brake pedal
❑ Removing and installing ⇒ page 28
❑ Can be checked in “Guided Fault Finding” diagnostic tester
8 - Brake pedal position sender - G100-
❑ In vehicles after week 45/05
❑ Location: on brake pump
❑ Removing and installing ⇒ page 28
❑ Can be checked in “Guided Fault Finding” diagnostic tester
9 - TCS and ESP button - E256-
❑ Location: in centre console.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
10 - Diagnostic connection
❑ Installation area: cover in footwell on the driver side
11 - Revolution sensor for the front right hand wheel - G45 - / Revolution sensor for the front left hand wheel -
G47 -
❑ Can be checked in “Guided Fault Finding” diagnostic tester
❑ Removing and installing ⇒ page 63
12 - Wheel bearing housing
13 - Wheel hub with wheel bearing
❑ The ABS sensor ring is fitted in the wheel bearing
14 - Rear right speed sensor - G44 - / rear left speed sensor - G46-
❑ Can be checked in “Guided Fault Finding” diagnostic tester
❑ Removal and assembly (front-wheel drive) ⇒ page 65
❑ Removal and assembly (four-wheel drive) ⇒ page 67
15 - Rear axle body with axle journal
16 - Wheel hub with wheel bearing
❑ The ABS sensor ring is fitted in the wheel bearing

3. Electrical/electronic components and locations 13

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

3.2 ABS Mark 70 -ABS/ASR/EBV/RKA- (after week 22.08)

1 - ABS control unit - J104-

❑ Assembly location: in
the hydraulic control
unit, in the engine com‐
partment, to the right
❑ Can be checked in “Gui‐
ded Fault Finding” diag‐
nostic tester
❑ Do not separate con‐
nector before success‐
fully completing self-di‐
agnosis. Switch ignition
off before separating
connector.
❑ Removing and installing
⇒ page 44
2 - Hydraulic units for the ABS.
- N55-
❑ Fitting location: in en‐
gine compartment
(right-side)
The hydraulic unit consists of
the following components:
❑ ABS hydraulic pump -
V64-
❑ Can be checked in “Gui‐
ded Fault Finding” diag‐
nostic tester
❑ Valve block (contains in‐
let and outlet valves).
❑ The ABS hydraulic
pump - V64- must not be
separated from the
valve block.
❑ Removing and installing
⇒ page 44
3 - TCS and ESP button - E256-
❑ Location: in by
Protected centre console.
copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
4 - Diagnostic connection
respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ Installation area: cover in footwell on the driver side

5 - Rear right speed sensor - G44 - / rear left speed sensor - G46-
❑ Can be checked in “Guided Fault Finding” diagnostic tester
❑ Removal and assembly (front-wheel drive) ⇒ page 65
❑ Removal and assembly (four-wheel drive) ⇒ page 67
6 - Wheel hub with wheel bearing
❑ The ABS sensor ring is fitted in the wheel bearing
7 - Rear axle body with axle journal
8 - Wheel hub with wheel bearing
❑ The ABS sensor ring is fitted in the wheel bearing

14 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

9 - Wheel bearing housing

10 - Revolution sensor for the front right hand wheel - G45 - / Revolution sensor for the front left hand wheel -
G47-
❑ Can be checked in “Guided Fault Finding” diagnostic tester
❑ Removing and installing ⇒ page 63
11 - Brake pedal position sender - G100-
❑ Location: on brake pump
❑ Removing and installing ⇒ page 28
❑ Can be checked in “Guided Fault Finding” diagnostic tester

1 - Dash panel insert up to

week 12.2009
12 - Brake system indicator -
K118-
❑ Brake malfunction,
handbrake
❑ If flashing, check the
brake fluid level
❑ Function: ⇒ page 21
13 - ABS warning lamp - K47-
❑ Function: ⇒ page 21
14 - Brake pad warning lamp -
K32-
❑ Function: ⇒ page 21
15 - Traction control system
warning lamp - K86-
❑ Function: ⇒ page 21
2 - Dash panel insert from
week 12.2009
16 - Brake system indicator -
K118-
❑ Brake malfunction,
handbrake
❑ If flashing, check the
brake fluid level
❑ Function: ⇒ page 24
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
17 - ABS warning lamp - K47- permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Function: ⇒ page 24
18 - Tyre pressure control indi‐
cator, RKA - K220-
❑ For more information about the functionality of the RKA, see Workshop Manual ⇒ Running gear, axles,
steering; Rep. gr. 44
19 - Traction control system warning lamp - K86-
❑ Function: ⇒ page 24

3. Electrical/electronic components and locations 15

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

3.3 ABS Mark 60 -ABS/EDS/ASR/ESP- (until week 22.08)

1 - ABS control unit - J104-

❑ Assembly location: in
the hydraulic control
unit, in the engine com‐
partment, to the right
❑ Can be checked in “Gui‐
ded Fault Finding” diag‐
nostic tester
❑ Do not separate con‐
nector before success‐
fully completing self-di‐
agnosis. Switch ignition
off before separating
connector.
❑ Removing and installing
⇒ page 51
2 - Hydraulic units for the ABS.
- N55-
❑ Fitting location: in en‐
gine compartment
(right-side)
The hydraulic unit consists of
the following components:
❑ ABS hydraulic pump -
V64-
❑ Brake pressure sender
1 - G201-
❑ Can be checked in “Gui‐
ded Fault Finding” using
vehicle diagnostic tester
❑ Valve block (contains in‐
let and outlet valves).
❑ The ABS hydraulic
pump - V64- must not be
separated from the
valve block
❑ Removing and installing ⇒ page 51
3 - Brake system indicator - K118-
❑ Location: in dash panel insert.
❑ Function: ⇒ page 21
4 - ABS warning lamp - K47-
❑ Location: in dash panel insert.
❑ Function: ⇒ page 21 permitted
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
5 - Stability Program Indicator, ASR/ESP - K155-
❑ Only in vehicles fitted with ABS/EDS/ASR/ESP
❑ Location: in dash panel insert.
❑ Function: ⇒ page 21
6 - Brake pad warning lamp - K32-
❑ Location: in dash panel insert.
❑ Function: ⇒ page 21
7 - Brake light switch - F- and brake pedal switch - F47-
❑ In vehicles prior to week 45/05

16 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

❑ Location: on brake pedal

❑ Removing and installing ⇒ page 28
❑ Can be checked in “Guided Fault Finding” diagnostic tester
8 - Brake pedal position sender - G100-
❑ In vehicles after week 45/05
❑ Location: on brake pump
❑ Removing and installing ⇒ page 28
❑ Can be checked in “Guided Fault Finding” diagnostic tester
9 - TCS and ESP button - E256-
❑ Only in vehicles fitted with ABS/EDS/ASR/ESP
❑ Location: in centre console.
10 - ESP sensor unit - G419-
❑ Only in vehicles fitted with ABS/EDS/ASR/ESP
❑ Location: behind passenger seat
❑ Combination of Transversal acceleration sender - G200 - , turn magnitude sensor - G202- and longitu‐
dinal acceleration sender - G251-
❑ Integrated into one casing
❑ Can be checked in “Guided Fault Finding” diagnostic tester
❑ Removing and installing ⇒ page 29
11 - Steering angle sender - G85-
❑ Installation location: on the steering column between the steering wheel and the steering wheel lever.
❑ Can be checked in “Guided Fault Finding” diagnostic tester
❑ Removing and installing ⇒ page 31
12 - Diagnostic connection
❑ Installation area: cover in footwell on the driver side
13 - Revolution sensor for the front right hand wheel - G45- / Revolution sensor for the front left hand wheel -
G47-
❑ Can be checked in “Guided Fault Finding” diagnostic tester
❑ Removing and installing ⇒ page 63
14 - Wheel bearing housing
15 - Wheel hub with wheel bearing
❑ The ABS sensor ring is fitted in the wheel bearing
16 - Rear right speed sensor - G44 - / rear left speed sensor - G46-
❑ Can be checked in “Guided Fault Finding” diagnostic tester
❑ Removing and installing ⇒ page 65
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
17 - Wheel
permitted bearing
unless authorised housing
by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Figure for front traction

18 - Wheel hub with wheel bearing

❑ The ABS sensor ring is fitted in the wheel bearing

3. Electrical/electronic components and locations 17

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

3.4 ABS Mark 60 -ABS/EDS/ASR/ESP/

RKA+/EBA/DSR - HHC (from week
22.08) - XDS 1 2 - NBA 3
1 For Cupra R, from week 36.09
2 For all other models from week 45.09
3 From week 22.10

1 - ABS control unit - J104-

❑ Removing and installing

⇒ page 58
2 - Hydraulic units for the ABS.
- N55-
❑ Fitting location: in en‐
gine compartment
(right-side)
The hydraulic unit consists of
the following components:
❑ ABS hydraulic pump -
V64-
❑ Brake pressure sender
1 - G201-
❑ Can be checked in “Guided Fault Finding” using vehicle diagnostic tester
❑ Valve block (contains inlet and outlet valves).
❑ The ABS hydraulic pump - V64- must not be separated from the valve block
❑ Removing and installing ⇒ page 58
3 - Button for TCS and ESP - E256 - , up to week 12.09
❑ Only in vehicles fitted with ABS/EDS/ASR/ESP
❑ Location: in centre console.
4 - Button for TCS and ESP - E256 - , from week 12.09
❑ Only in vehicles fitted with ABS/EDS/ASR/ESP

18 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

❑ Location: in centre console.

5 - Diagnostic connection
❑ Installation area: cover in footwell on the driver side
6 - Steering angle sender - G85-
❑ Installation location: on the steering column between the steering wheel and the steering wheel lever.

Note

On vehicles with 3rd generation

electro-mechanical steering aid, the
steering angle sensor is located in
the steering gear
❑ Can be checked in “Guided Fault Finding” diagnostic tester
❑ Removing and installing ⇒ page 31
7 - Wheel hub with wheel bearing
❑ The ABS sensor ring is fitted in the wheel bearing
8 - Wheel bearing housing
Figure for front traction
9 - Rear right speed sensor - G44 - / rear left speed sensor - G46-
❑ Can be checked in “Guided Fault Finding” diagnostic tester
❑ Removing and installing ⇒ page 65
10 - Wheel hub with wheel bearing
❑ The ABS sensor ring is fitted in the wheel bearing
11 - Wheel bearing housing
12 - Revolution sensor for the front right hand wheel - G45 - / Revolution sensor for the front left hand wheel -
G47-
Protected ❑ Can be
by copyright. checked
Copying inor“Guided
for private Fault Finding”
commercial purposes, diagnostic
in part or in whole, is not tester
❑
permitted unless Removing
authorised and
by SEAT S.A.installing
SEAT S.A does ⇒ page
not 63
guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
13 - Brake pedal position sender - G100-
❑ Location: on brake pump
❑ Removing and installing ⇒ page 28
❑ Can be checked in “Guided Fault Finding” diagnostic tester

3. Electrical/electronic components and locations 19

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

1 - Dash panel insert up to

week 12.2009
14 - Brake system indicator -
K118-
❑ Function: ⇒ page 21
15 - ABS warning lamp - K47-
❑ Function: ⇒ page 21
16 - Brake pad warning lamp -
K32-
❑ Function: ⇒ page 21
17 - Stability Program Indica‐
tor, ASR/ESP - K155-
❑ Only in vehicles fitted
with ABS/EDS/ASR/
ESP
❑ Function: ⇒ page 21
2 - Dash panel insert from
week 12.2009
18 - Brake system indicator -
K118-
❑ Brake malfunction,
handbrake
❑ If flashing, check the
brake fluid level
❑ Function: ⇒ page 24
19 - ABS warning lamp - K47-
❑ Function: ⇒ page 24
20 - Tyre pressure control indi‐
cator, RKA - K220-
❑ For more information
about the functionality of the RKA, see Workshop Manual ⇒ Running gear, axles, steering; Rep. gr. 44
21 - Warning lightbyfor
Protected selector
copyright. lever
Copying lockor-commercial
for private K169- purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ For models with
respect to theautomatic gearboxin only
correctness of information this document. Copyright by SEAT S.A.
❑ Function: ⇒ page 24
22 - Traction control system warning lamp - K86-
❑ Only in vehicles fitted with ABS/EDS/ASR/ESP
❑ Function: ⇒ page 24
23 - Warning lamp for deactivated ESP
❑ From week 22.10
❑ Function: ⇒ page 24

20 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

4 Viewing the faults indicated by the

control warning lamps
⇒ “4.1 Warning lamp in the dash panel insert up to week 12.2009”,
page 21
⇒ “4.2 Warning lamp in the dash panel insert from week 12.2009”,
page 24

4.1 Warning lamp in the dash panel insert

up to week 12.2009
Instrument panel warning lights for ABS Mark 70 system
Item Designation
1 Brake system indicator - K118-
2 ABS warning lamp - K47-
3 Brake pad warning lamp - K32-
4 Traction control system warning lamp - K86-

4. Viewing the faults indicated by the control warning lamps 21

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

Instrument panel warning lights for ABS Mark 60 system

Item Designation
1 Brake system indicator - K118-
2 ABS warning lamp - K47-
3 Brake pad warning lamp - K32-
4 Stability Program Indicator, ASR/ESP - K155-
Brake pad warning lamp - K32-
♦ If the brake pad indicator - K32- -3- does not go out 3 seconds
after switching on the ignition or if it lights up when driving, this
may be for several reasons:
-a- Brake pads are worn.
Check front and rear brake pads: Replace if worn.
-b- There is a fault in the wiring ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations.
ABS warning lamp - K47-
♦ If the ABS indicator - K47- -2- does not go out after switching
on the ignition and on completion of the test process, this may
be for the following reasons:
-a- The voltage supply is less than 10 volts.
-b- An error has occurred in the ABS.

WARNING

If there is an ABS fault, -b-, the system will remain off while the
conventional braking system will continue working correctly.

indicator - K118- -1- remains lit, this may due to the following:
-a- The hand brake is on.
-b- The brake fluid level is too low (the warning light flashes).
When the ignition is switched on, 3 warning beeps can be heard.
-c- There is fault in the wiring of the brake system indicator - K118-
⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐
tions.
♦ If the ABS indicator - K47- -2- and the brake system indicator
- K118- -1- light, this implies that the ABS system is faulty.
However, a change in braking behaviour must be reckoned
with.

22 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

WARNING

If both the ABS indicator - K47- and the brake system indicator
- K118 - have come on, the rear wheels could lock before time
on braking.

Traction control system warning lamp - K86-

♦ If, after the ignition has been switched on and the test process
completed, the acceleration anti-skid regulation indicator -
K86- -4- does not go out, this may be due to the following:
There is a fault which only affects the ASR. The ABS and EBV
safety systems continue to run trouble free. Read fault memory.
-a- There is short to positive in the ASR/ESP button - E256 - .
-b- There is a fault in the activation of the acceleration slip regu‐
lation indicator - K86- ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
-c- The ASR system has been switched off using the ASR/ESP
button - E256 - .
If the acceleration slip regulation indicator - K86- flashes while
driving, this implies that the ASR system is in operation.
♦ If the acceleration slip regulation indicator - K86- -4- did not
light up during the auto-test, this implies the following fault:
-a- The warning lamp for the acceleration slip regulation indicator
- K86- is defective. Carry out an electric test.
Stability Program Indicator, ASR/ESP - K155-
♦ If, after the ignition has been switched on and the test process
completed, the the electronic stability program indicator, ASR/
ESP - K155- -4- does not go out, this may be due to the fol‐
lowing:
There is a fault which only affects the ASR/ESP. The ABS / EBS
and EBV safety systems continue to run trouble free. Read fault
memory.
-a- There is short to positive in the ASR/ESP button - E256 - .
-b- There is a fault in the activation of the ASR/ESP stability pro‐
gram indicator - K155- ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
-c- The ASR/ESP system has been switched off using the ASR/
ESP button - E256 - .
If the ASR/ESP indicator - K155- flashes while driving, this implies
that the ASR or ESP system is in operation.
♦ If the ASR/ESP indicator - K155- -4- did not light up during the
auto-test, this implies the
Protected following
by copyright. fault:
Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
-a- The warning lamp for the tostability
respect programme
the correctness of informationASR / ESP -Copyright by SEAT S.A.
in this document.
K155- is defective. Carry out an electric test.

4. Viewing the faults indicated by the control warning lamps 23

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

4.2 Warning lamp in the dash panel insert

from week 12.2009
Instrument panel warning lights for ABS Mark 70 system
Item Designation
1 Brake system indicator - K118-
2 ABS warning lamp - K47-
3 Signal lamp for tyre pressure warning lamp - K220-
1)

4 Traction control system warning lamp - K86-

1) For more information about the functionality of the RKA, see Workshop Manual
⇒ Running gear, axles, steering; Rep. gr. 44

24 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

Instrument panel warning lights for ABS Mark 60 system

Item Designation
1 Brake system indicator - K118-
2 ABS warning lamp - K47-
3 Signal lamp for tyre pressure warning lamp - K220-
2)

4 Warning lamp for selector lever lock - K169 - , only for

models with automatic gearbox
5 Stability Program Indicator, ASR/ESP - K155-
6 Warning lamp for deactivated ESP , from week
22.2010
2) For more information about the functionality of the RKA, see Workshop Manual
⇒ Running gear, axles, steering; Rep. gr. 44

ABS warning lamp - K47-

♦ If the ABS indicator - K47- -2- does not go out after switching
on the ignition and on completion of the test process, this may
be for the following reasons:
-a- The voltage supply is less than 10 volts.
-b- An error has occurred in the ABS.

WARNING

If there is an ABS fault, -b-, the system will remain off while the
conventional braking system will continue working correctly.

-c- since the last time the vehicle was started there was a tem‐
porary speed sensor fault.
In this case, the ABS warning light automatically switches off
when the vehicle starts moving again and is travelling at over 20
km/h.
-d- Connection between the instrument panel and the ABS control
unit - J104- has been interrupted ⇒ Current flow diagrams, Elec‐
trical fault finding and Fitting locations.
-e- There is a fault in the instrument panel.
ABS indicator - K47- and brake system indicator - K118-
♦ If the ABS indicator - K47- -2-, goes out, but the brake system
indicator - K118- -1- remains lit, this may due to the following:
-a- The hand brake is on.
-b- The brake fluid level is too low (the warning light flashes).
When the ignition is switched on, 3 warning beeps can be heard.
-c- Brake pads are worn (when fitted with brake pad wear sender).
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
-d- There
permitted is faultbyinSEAT
unless authorised theS.A.
wiring of does
SEAT S.A the not
brake system
guarantee or acceptwarning light -
any liability with
K118-
respect⇒toCurrent flowof diagrams,
the correctness Electrical
information in this fault finding
document. Copyright and Fitting
by SEAT S.A.
locations.
♦ If the ABS indicator - K47- -2- and the brake system indicator
- K118- -1- light, this implies that the ABS system is faulty.
However, a change in braking behaviour must be reckoned
with.

4. Viewing the faults indicated by the control warning lamps 25

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

WARNING

If both the ABS indicator - K47- and the brake system indicator
- K118 - have come on, the rear wheels could lock before time
on braking.

Traction control system warning lamp - K86-

There is a fault which only affects the ASR/ESP. The ABS / EBS
and EBV safety systems continue to run trouble free. Read fault
memory.
-a- There is short to positive in the ASR/ESP button - E256 - .
-b- There is a fault in the activation of the ASR/ESP stability pro‐
gram indicator - K155- ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations.
-c- The ASR/ESP system has been switched off using the ASR/
ESP button - E256 - .
If the ASR/ESP indicator - K155- flashes while driving, this implies
that the ASR or ESP system is in operation.
♦ If the ASR/ESP indicator - K155- -4- did not light up during the
auto-test, this implies the following fault:
-a- The warning lamp for the stability programme ASR / ESP -
K155- is defective. Carry out an electric test.
Warning lamp for deactivated ESP , from week 22.2010
This indicates that the traction control system (TCS) is deactiva‐
ted.
♦ It remains turned on when the TCS is deactivated by pressing
the button for TCS and ESP - E256 - .
Warning light for selector lever lock - K169-
For models with automatic gearbox only.

26 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

♦ If this is turned on, the brake pedal must be pressed so that

the automatic gear lever can be moved from the P position to
N.

4. Viewing the faults indicated by the control warning lamps 27

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

5 ABS/ESP system components: re‐

moving and fitting
⇒ “5.1 Brake light switch F and Brake pedal position sender
G100 : installation and removal”, page 28
⇒ “5.2 ESP sensor unit G419 :removing and installing”,
page 29
⇒ “5.3 Removing and installing steering angle sender G85 ”, page
31
⇒ “5.4 Braking pressure sender -1- G201 : removing and instal‐
ling”, page 32
⇒ “5.5 Vacuum transmitter of the brake servo G483 : installation
and removal”, page 33

5.1 Brake light switch - F- and Brake pedal

position sender - G100- : installation and
removal
Brake light switch - F- up to week 45/05 ⇒ page 28 .
Brake pedal position sender - G100 - up to week 45/05
⇒ page 29 . Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

5.1.1 Brake light switch - respect

F- : toprior to week
the correctness of information in this document. Copyright by SEAT S.A.

45/05: removing and installing

Note

Switch may only be fitted once so as to ensure a firm fit.

Removing
– Remove the lower trim of the driver's side foot well ⇒ Body‐
work, interior work; Rep. gr. 68 ; Stowage compartment,
coverings and trims .
– Release the connector from the light control switch and re‐
move it from its bracket by rotating it 45° to left.
Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:
– Pull out plunger of brake light switch as far as it will go
-arrow-.
– Fit the switch by inserting the securing tabs -1 and 2- into the
designated grooves in the opening and secure by rotating 45°
to the right.
– Connect the connector to the brake light switch.

Note

♦ Do not press brake pedal when installing.

♦ When inserting the brake light switch, the push rod is auto‐
matically adjusted.

– Check the operation of the brake lights by operating and re‐

leasing the brake pedal.

28 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

5.1.2 Brake pedal position sender - G100- :

after 45/05: removing and fitting
In vehicles manufactured prior to week 45/05, the brake light
switch is located on the brake pedal.
Removing
– Remove engine cover
– In some vehicles it is necessary to remove the intake hose.
– Disconnect the connector -1- of the brake pedal position send‐
er - G100- .
– Loosen the bolt -2- of the brake pump.
– Remove the brake pedal position sender - G100- -3- under the
brake pump and remove it upwards from the support flange
-4-.
Installing
– Install in reverse order.
Specified torque:
Torx bolt to the brake pump 5 Nm

5.2 ESP sensor unit - G419 - :removing and

installing
⇒ “5.2.1 ESP sensor unit G419 :removing and installing”,
page 29
⇒ “5.2.2 ESP sensor unit G419 for the brake system Mark 60
(from week 22.08)”, page 31

5.2.1 ESP sensor unit - G419 - :removing and

installing
Removing

Note

The ESP-Sensor unit contains the following senders: lateral ac‐

celeration sender - G200- and transversal acceleration sender -
G202- .

– Remove the passenger seat ⇒ Bodywork, interior work; Rep.

gr. 72 ; Front seats .
– Remove the foot well cover (on the passenger side), lift the
carpet and the insulation ⇒ Interior fitting work; Rep. gr. 68 ;
Interior upholstery: removing and fitting .
The -arrow F- in the illustration represents forward direction of
vehicle.

5. ABS/ESP system components: removing and fitting 29

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Remove the connector -2- from the ESP sensor unit.

– Remove the bolts -4- and remove the ESP sensor unit up‐
wards -1-.
– Pos. -3- is for the cross member of the seat.

Note

♦ The ESP sensor unit is sensitive to hard shocks.

♦ If the ESP sensor unit is dropped, it may cease to function
correctly. In this case, the unit should not be used.

Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:
– Calibrate the transversal acceleration sender - G200 -
– Making the ESP operation test.

Note

The ESP test drive is used to check the validity of the signals from
the brake pressure sender-1- - G201 - , from the transversal ac‐
celeration sender - G200- and the turn magnitude sender - G202
-.

Use vehicle diagnosis device for this purpose.

– Connect the vehicle diagnosis device to the vehicle adapter
and then select the function test in “Function/Component se‐
lection” ⇒ page 11 .
– Then:
– “Running gear”
– “Brake system”
– “01 - Self-diagnosis systems Mark 60/Mark 70”
– “03 - ABS/EDS/ASR/ESP Mark 60/Mark 70”
– “Functions”
– “ESP test drive”
Use vehicle diagnosis device for this purpose.
– Connect the vehicle diagnosis device to the vehicle adapter
and then select the function test in “Function/Component se‐
lection” ⇒ page 11 .
– Then:
– “Running gear”
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– “Brake system” permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– “01 - Self-diagnosis systems Mark 60/Mark 70”
– “03 - ABS/EDS/ASR/ESP Mark 60/Mark 70”
– “Components:”
– “G200 - Transversal acceleration sender” ⇒ Vehicle diagnostic
tester in the function “Guided fault finding”

30 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

5.2.2 ESP sensor unit - G419 - for the brake

system Mark 60 (from week 22.08)

Note

The ESP sensor unit - G419- (a combination of transversal ac‐

celeration transmitters - G200 - , yaw rate sender - G202 - and
longitudinal acceleration sender - G251 - ) is integrated in the ABS
control unit - J104 - ⇒ Item 1 (page 18)

5.2.3 Specified torque

Component Nm
ESP sensor unit to the bracket 20

5.3 Removing and installing steering angle

sender - G85 -
The steering wheel angle sender - G85- is fitted between the
steering wheel and the combination switch of the steering column.

Note

On vehicles with 3rd generation electro-mechanical steering aid,

the steering angle sensor is located in the steering gear

5.3.1 Removing

WARNING

The following are prerequisites before starting work on the

electrical system and removing the steering wheel:
Put the front wheels straight.
Ensure that the ignition key is not in the engine ignition lock.
Disconnect the earth lead from the battery ⇒ Electrical system;
Rep. gr. 27 ; Starter motor, voltage supply; Battery .
If these instructions are not followed then the airbag system
could fail later!

– Put the front wheels straight.

– Pull down lever beneath steering column.
– Pull the steering column down as far as possible and remove.
– Removal of the steering wheel ⇒ Interior fitting work; Rep. gr.
69 ; Passenger protection; Airbag .
– Fit the steering column combination switch trimming, ⇒ Elec‐
trical system; Rep. gr. 94 ; Lights, lamps and exterior switches;
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Steering column
respect combination
to the correctness switch
of information . document. Copyright by SEAT S.A.
in this

– Remove the switching module on the steering column ⇒ Elec‐

trical system; Rep. gr. 94 ; Lights, bulbs and exterior switches .

5. ABS/ESP system components: removing and fitting 31

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Carefully extract the assembly/retainer ring with the contact

friction ring -1-.

– Carefully remove the steering wheel angle sender - G85-

-arrow-.

WARNING

The retainer ring with the contact friction ring must not be ro‐
tated when separated.

5.3.2 Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:
– Begin calibration of the steering wheel angle sender - G85 - .
– Making the ESP operation test.
Use vehicle diagnosis device for this purpose.
– Connect the vehicle diagnosis device to the vehicle adapter
and then select the function test in “Function/Component se‐
lection” ⇒ page 11 .
– Then:
– “Running gear”
– “Brake system”
– “01 - Self-diagnosis systems Mark 60/Mark 70”
– “03 - ABS/EDS/ASR/ESP Mark 60/Mark 70”
– “Components:”
– “G85 - Steering angle sender” ⇒ Vehicle diagnostic tester us‐
ing the function “Guided fault finding”
– Connecting the vehicle diagnosis device ⇒ page 11 .

5.4 Braking pressure sender -1- - G201 - :

removing and installing
Special tools and workshop equipment required

32 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

♦ Brake de-airing device - SAT 1175B -

5.4.1 Removing

Note

The brake pressure sender -1- - G201- is integrated in the ABS

hydraulic unit - N55 - .

– Removing and installing the hydraulic unit - N55 - anti-lock

brake system (ABS). ⇒ page 51 .

5.4.2 Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:
– Bleeding air from the brake system ⇒ page 163 .
– Bleeding air from the clutch hydraulic system ⇒ 5 speed man‐
ual gearbox; Rep. gr. 30 ; Clutch; Hydraulic system: removing
and fitting .
– Initiate the calibration of the Brake pressure sender 1 - G201
-.
– Makingpermitted
the ESP unlessoperation test.S.A. SEAT S.A does not guarantee or accept any liability with
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
authorised by SEAT
respect to the correctness of information in this document. Copyright by SEAT S.A.
Use vehicle diagnosis device for this purpose.
– Connect the vehicle diagnosis device to the vehicle adapter
and then select the function test in “Function/Component se‐
lection” ⇒ page 11 .
– Then:
– “Running gear”
– “Brake system”
– “01 - Self-diagnosis systems Mark 60/Mark 70”
– “03 - ABS/EDS/ASR/ESP Mark 60/Mark 70”
– “Components:”
– “G201 - Brake pressure sender 1”

5.5 Vacuum transmitter of the brake servo -

G483 - : installation and removal
Removing
– Battery: removing and installing⇒ Electrical system; Rep. gr.
27 ; Battery: removing and installing .
– Remove battery tray.

5. ABS/ESP system components: removing and fitting 33

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Disconnect the connector -1- from the servo brake vacuum

sender - G483- -2-.

– Place a screwdriver in the groove of the securing ring -1-, be‐

tween the limit and one of the edges of the ring.
– Release the securing ring -1- from the groove until it is possible
to remove the servo brake vacuum sender - G483- -2- of the
servo brake.
Installing
– Install in reverse order.

34 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

6 Hydraulic unit, brake servo/brake

master cylinder: Assembly overview
⇒ “6.1 ABS Mark 70 -ABS/ASR- (until week 22.08)”, page 35
⇒ “6.2 ABS Mark 70 -ABS/ASR/EBV/RKA- (after week 22.08)”,
page 41
⇒ “6.3 ABS Mark 60 -ABS/EDS/ASR/ESP- (until week 22.08)”,
page 48
⇒ “6.4 ABS Mark 60 -ABS/EDS/ASR/ESP/RKA+/EBA/DSR-
(from week 22.08)”, page 56

6.1 ABS Mark 70 -ABS/ASR- (until week 22.08)

1 - ABS control unit - J104-

❑ Removing and installing
⇒ page 37
2 - Hydraulic units for the ABS.
- N55-
❑ Removing and installing
⇒ page 37
3 - Brake line
❑ From primary piston cir‐
cuit of brake master cyl‐
inder to hydraulic unit.
❑ Specifications: threa‐
ded pipe bolt M 10 x 1
4 - Brake line
❑ From secondary piston
circuit of brake master
cylinder to hydraulic
unit.
❑ Specifications: threa‐
ded pipe bolt M 12 x 1
5 - Brake line
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ To unless
permitted the front leftbybrake
authorised SEAT S.A. SEAT S.A does not guarantee or accept any liability with
calliper
respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ Specifications: threa‐
ded pipe bolt M 12 x 1
6 - Brake line
❑ To the front right brake
calliper
❑ Specifications: threa‐
ded pipe bolt M 10 x 1
7 - Brake line
❑ To the rear left brake
calliper
❑ Specifications: threaded pipe bolt M 12 x 1
8 - Brake line
❑ To the rear right brake calliper
❑ Specifications: threaded pipe bolt M 10 x 1
9 - Torx screw 5.5 Nm
❑ Use new bolts.

6. Hydraulic unit, brake servo/brake master cylinder: Assembly overview 35

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

10 - Bracket
11 - Hexagon bolt, 8 Nm
12 - Seal
❑ For brake servo.
13 - Brake servo
❑ In petrol engines the vacuum required is taken from the intake manifold.
❑ In diesel engines the vacuum is obtained by a fitted vacuum pump ⇒ page 173
❑ Functional check:
– With engine off, press the brake pedal hard several times (this reduces the existing vacuum in the servo
brake).

6.1.1 Connection of the tandem master cylin‐

der brake lines to the hydraulic unit
On the tandem master cylinder:
A - Master brake cylinder/pressure-bar piston circuit to hydraulic
unit.
- Specifications: threaded pipe bolt M10 x 1.
B - From master brake cylinder/floating piston circuit to hydraulic
unit.
- Specifications: threaded pipe bolt M12 x 1.
1 - Hydraulic unit to front left brake calliper.
3 - Hydraulic unit
Protected by to rear
copyright. right
Copying brakeor calliper.
for private commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
4 - Hydraulic unit to rear left brake calliper.
respect to the correctness of information in this document. Copyright by SEAT S.A.

36 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

On the hydraulic unit:

A - From hydraulic unit to master brake cylinder/pressure-bar pis‐
ton circuit.
- Specifications: threaded pipe bolt M10 x 1.
B - From hydraulic unit to master brake cylinder/floating piston
circuit.
- Specifications: threaded pipe bolt M12 x 1.
1 - Hydraulic unit to front left brake calliper.
- Specifications: threaded pipe bolt M12 x 1.
2 - Hydraulic unit to front right brake calliper.
- Specifications: threaded pipe bolt M10 x 1.
3 - Hydraulic unit to rear right brake calliper.
- Specifications: threaded pipe bolt M10 x 1.
4 - Hydraulic unit to rear left brake calliper.
- Specifications: threaded pipe bolt M12 x 1.

6.1.2 ABS control unit - J104- and ABS control

unit and ABS hydraulic unit - N55 - : re‐
moval.
Special tools and workshop equipment required
♦ Brake pedal depressor - V.A.G 1869/2-

♦ Calliper set for repairs; part number according to ⇒ Parts

catalogue

6. Hydraulic unit, brake servo/brake master cylinder: Assembly overview 37

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

1 - Valve dome transport protection (rubber foam).

2 - Caps M10 for brake lines and screw holes.
3 - Caps M12 for brake lines and screw holes.
After removing the control unit of the hydraulic unit, the transpor‐
tation protection for the hydraulic unit valve stems must always
be applied.
No guarantee is given for hydraulic units without transport pro‐
tection.
Removing
Location:
The control unit is bolted to the hydraulic unit and is located on
the right side of the engine compartment.

WARNING

The brake lines should not be folded or kinked in area of the

hydraulic unit

– Check and note the code for the control unit fitted.
– Note or request radio code on vehicles with coded radio if
necessary.
– Disconnecting the battery ⇒ Electrical system; Rep. gr. 27 ;
Disconnecting and connecting battery
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove
permittedengine coverby SEAT S.A. SEAT S.A does not guarantee or accept any liability with
unless authorised
respect to the correctness of information in this document. Copyright by SEAT S.A.
1.9 l diesel engine:
– Loosen the connecting hose on the intake support ⇒ 4 cylinder
Diesel (2 valve); Rep. gr. 21 ; Charged air system with exhaust
gas turbocharger .
– Remove the intake manifold flap motor - V157- ⇒ 4-cylinder
diesel (2 valves); Rep. gr. 23 ; mixture preparation, injection .
2.0l diesel engine:
– Remove the front panel of the plenum chamber ⇒ Bodywork,
exterior fitting work; Rep. gr. 50 ; Front panel of the plenum
chamber: assembly overview .
– Remove the connection tube between the intake hose and the
exhaust gas turbocharger.
– Remove upper notched belt guard.
Diesel engines with particle filter:
– Unbolt the exhaust gas pressure sensor 1, - G450 - disconnect
electrical connections and unbolt and lower particulate filter ⇒
Front section of exhaust pipe with particulate filter: Assembly
overview; Rep. gr. 26 :

38 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

All vehicles (continued):

– Disengage the control unit connector in the direction shown
on the arrow -1- and remove -2-.
– Fit the block for the brake pedal - VAG 1869/2- .
– Plug the hose of the air bleeding bottle to the vent valve of the
brake calliper in the front and back left and open the vent valve.
– Operate the brake pedal using the brake pedal block - VAG
1869/2- 60 mm minimum.
– Close the front and rear left bleeding screws.
– Do not remove the block for the brake pedal - VAG 1869/2- .
– Place a sufficiently large lint-free cloth under the control unit
and the hydraulic unit.

WARNING

Make sure that brake fluid does not fall onto the connectors.

– Mark both brake master cylinder brake lines -A and B- before

– Pull the hydraulic unit with the control unit upwards to remove
the shock absorbers.

6.1.3 Unscrew the ABS control unit - J104-

from the ABS hydraulic unit - N55- .
– Place the ABS control unit - J104- with the ABS hydraulic unit
- N55- upwards on a clean and flat surface.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

6. Hydraulic unit, brake servo/brake master cylinder: Assembly overview 39

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Screw out Torx bolts -arrows-.

– Remove the ABS hydraulic unit - N55- -arrow- perpendicularly

without tilting.
– Carefully remove all the seals to the hydraulic unit valve stems.

WARNING

♦ When the control unit has been removed, the printed cir‐
cuit board is visible.
♦ Do not allow dirt or damp to enter the control unit.
♦ Hydraulic pump is not to be separated from hydraulic unit.
♦ Avoid electrostatic discharge!

– Cover the control unit solenoids with a lint-free cloth.

– After separating the control unit from the hydraulic unit, cover
the valves with the transport protection.

6.1.4 Fitting a new control Protected

unit -byJ104-
copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
WARNING

Sharp movements (for example, dropping or knocking) may

destroy the control unit. The control unit is useless and must
not be used!

• Clean the surfaces before fitting.

40 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Insert the seals -A- a little way into the valve stems.
– Fit the ABS control unit - J104- to the ABS hydraulic unit - N55-
ensuring this is straight.

Note

This pushes the seals into their final position.

– Bolt control unit to hydraulic unit with the new Torx bolts sup‐
plied.

Note

♦ The same hydraulic unit should not be fitted with a new control
unit more than twice, otherwise the elastic seal will not provide
a suitable seal.
♦ A control unit which has been fitted previously should not be
fitted again.

6.1.5 ABS control unit - J104- and ABS hy‐

draulic unit - N55 - : installation

Note

♦ Do not remove the anti-humidity plugs until fitting the corre‐

sponding brake lines.
♦ If the plugs are removed from the control unit beforehand,
brake fluid may leak out, and therefore the fluid level and
bleeding will be incorrect.
♦ When assembling, ensure that the shock absorber rubbers do
not protrude from the console.

– Install in reverse order.

– Remove the block for the brake pedal - VAG 1869/2- .
– Bleeding air from the brake system ⇒ page 163 .
– Code radio.
– Code the ABS control unit - J104- using the "Guided fault lo‐
cation" of the ⇒ Vehicle diagnostic tester.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Specified torques: respect to the correctness of information in this document. Copyright by SEAT S.A.

Control unit to hydraulic unit 5.5 Nm

♦ Use new bolts!

Hexagon bolt of hydraulic unit to bracket 8 Nm

Brake lines to ABS group:
Thread M10 x 1 14 Nm
Thread M12 x 1 14 Nm

6.2 ABS Mark 70 -ABS/ASR/EBV/RKA- (after week 22.08)

6. Hydraulic unit, brake servo/brake master cylinder: Assembly overview 41

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

1 - ABS control unit - J104-

❑ Removing and installing
⇒ page 44
2 - Hydraulic units for the ABS.
- N55-
❑ Removing and installing
⇒ page 44
3 - Brake line
❑ From primary piston cir‐
cuit of brake master cyl‐
inder to hydraulic unit.
❑ Specifications: threa‐
ded pipe bolt M 10 x 1
4 - Brake line
❑ From secondary piston
circuit of brake master
cylinder to hydraulic
unit.
❑ Specifications: threa‐
ded pipe bolt M 12 x 1
5 - Brake line
❑ To the front left brake
calliper
❑ Specifications: threa‐
ded pipe bolt M 10 x 1
6 - Brake line
❑ To the front right brake
calliper
❑ Specifications: threa‐
ded pipe bolt M 10 x 1
7 - Brake line
❑ To the rear left brake
calliper
❑ Specifications: threaded pipe bolt M 12 x 1
8 - Brake line
❑ To the rear right brake calliper
❑ Specifications: threaded pipe bolt M 10 x 1
9 - Torx screw 5.5 Nm
❑ Use new bolts.
10 - Bracket
11 - Hexagon bolt, 8 Nm
12 - Seal
❑ For brake servo.
13 - Brake servo
❑ In petrol engines the vacuum requiredProtected
is taken from the intake manifold.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ In diesel engines the vacuum is obtained by a fitted vacuum
permitted unless authorised pump
by SEAT S.A. SEAT⇒ S.Apage 173
does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Functional check:
– With engine off, press the brake pedal hard several times (this reduces the existing vacuum in the servo
brake).

– Next, keep the brake pedal depressed halfway and start engine. If the brake servo is working correctly
the brake pedal will give way notably (the brake servo effect is beginning)

42 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

❑ If faulty, renew as a complete unit.

❑ Removing and installing ⇒ page 179
14 - Sealing ring
15 - Brake master cylinder
❑ Allocation: ⇒ Parts catalogue
❑ Cannot be repaired. If faulty, renew as a complete unit.
❑ Removing and installing ⇒ page 177
16 - Hexagon nut, 25 Nm
❑ Replace after each removal
17 - Seal cap
❑ Moisten with brake fluid and place the brake fluid reservoir under pressure
18 - Brake fluid reservoir
19 - Plug
20 - Seal cap
❑ Vacuum hose connection

6.2.1 Connection of the tandem master cylin‐

der brake lines to the hydraulic unit
On the tandem master cylinder:
A - Master brake cylinder/pressure-bar piston circuit to hydraulic
unit.
- Specifications: threaded pipe bolt M10 x 1.
B - From master brake cylinder/floating piston circuit to hydraulic
unit.
- Specifications: threaded pipe bolt M12 x 1.
1 - Hydraulic unit to front left brake calliper.
3 -permitted
Hydraulicunlessunit to rear right
S.A. brake
SEAT S.Acalliper.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
authorised by SEAT does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
4 - Hydraulic unit to rear left brake calliper.

On the hydraulic unit:

A - From hydraulic unit to master brake cylinder/pressure-bar pis‐
ton circuit.
- Specifications: threaded pipe bolt M10 x 1.
B - From hydraulic unit to master brake cylinder/floating piston
circuit.
- Specifications: threaded pipe bolt M12 x 1.
1 - Hydraulic unit to front left brake calliper.
- Specifications: threaded pipe bolt M10 x 1.
2 - Hydraulic unit to front right brake calliper.
- Specifications: threaded pipe bolt M10 x 1.
3 - Hydraulic unit to rear right brake calliper.
- Specifications: threaded pipe bolt M10 x 1.
4 - Hydraulic unit to rear left brake calliper.
- Specifications: threaded pipe bolt M12 x 1.

6. Hydraulic unit, brake servo/brake master cylinder: Assembly overview 43

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

6.2.2 ABS control unit - J104- and ABS control

unit and ABS hydraulic unit - N55 - : re‐
moval.
Special tools and workshop equipment required
♦ Brake pedal depressor - V.A.G 1869/2-

♦ Calliper set for repairs; part number according to ⇒ Parts

cataloguepermitted
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1 - Valve dome transport protection (rubber foam).

44 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

WARNING

The brake lines should not be folded or kinked in area of the

hydraulic unit

– Check and note the code for the control unit fitted.
– Note or request radio code on vehicles with coded radio if
necessary.
– Disconnecting the battery ⇒ Electrical system; Rep. gr. 27 ;
Disconnecting and connecting battery
– Remove engine cover
1.4 litre TSI engine:
– Remove the pressure hose and intake sleeve along with the
throttle valve module ⇒ 4 cylinder Injection engine (1.4 l Direct
injection valve, turbocharger and rotary piston compressor);
Rep. gr. 24 .
– Remove the air filter housing ⇒ 4 cylinder. Injection engine
(1.4 l Direct injection valve, turbocharger and rotary piston
compressor); Rep. gr. 21 .
– Loosen and remove the coolant hose from coolant expansion
tank.
1.9 l diesel engine:
– Loosen the connecting hose on the intake support ⇒ 4 cylinder
Diesel (2 valve); Rep. gr. 21 ; Charged air system with exhaust
gas turbocharger .
– Remove the intake manifold flap motor - V157- ⇒ 4-cylinder
diesel (2 valves); Rep. gr. 23 ; mixture preparation, injection .
2.0l diesel engine:
– Remove the connection tube between the intake hose and the
exhaust gas turbocharger.
– Remove upper notched belt guard.
Diesel engines with particle filter:
– Unbolt the exhaust gas pressure sensor 1, - G450 - disconnect
electrical connections and unbolt and lower particulate filter ⇒
Front section of exhaust pipe with particulate filter: Assembly
overview; Rep. gr. 26 :

6. Hydraulic unit, brake servo/brake master cylinder: Assembly overview 45

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

All vehicles (continued):

WARNING

Make sure that brake fluid does not fall onto the connectors.

– Mark both brake master cylinder brake lines -A and B- before

– Pull the hydraulic unit with the control unit upwards to remove
the shock absorbers.

6.2.3 Unscrew the ABS control unit - J104-

from the ABS hydraulic unit - N55- .
– Place the ABS control unit - J104- with the ABS hydraulic unit
- N55- upwards on a clean and flat surface.

46 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Screw out Torx bolts -arrows-.

– Remove the ABS hydraulic unit - N55- -arrow- perpendicularly

without tilting.
– Carefully remove all the seals to the hydraulic unit valve stems.

WARNING

– Cover the control unit solenoids with a lint-free cloth.

– After separating the control unit from the hydraulic unit, cover
the valves with the transport protection.

6.2.4 Fitting a new control unit for the ABS -

J104- installing

WARNING

Sharp movements (for example, dropping or knocking) may

destroy the control unit. The control unit is useless and must
not be used!

• Clean the surfaces before fitting.

6. Hydraulic unit, brake servo/brake master cylinder: Assembly overview 47

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Insert the seals -A- a little way into the valve stems.
– Fit the ABS control unit - J104- to the ABS hydraulic unit - N55-
ensuring this is straight.

Note

This pushes the seals into their final position.

– Bolt control unit to hydraulic unit with the new Torx bolts sup‐
plied.

Note

6.2.5 ABS control unit - J104- and ABS hy‐

draulic unit - N55 - : installation

Note

♦ Do not remove the anti-humidity plugs until fitting the corre‐

– Install in reverse order.

Hexagon bolt of hydraulic unit to bracket 8 Nm

Brake lines to ABS group:
Thread M10 x 1 14 Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Thread M12 x 1 14SEAT
permitted unless authorised by SEAT S.A. NmS.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

6.3 ABS Mark 60 -ABS/EDS/ASR/ESP- (until week 22.08)

48 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

1 - ABS control unit - J104-

On vehicles fitted with hydraul‐
ic servo brake or hill start assist
the control unit cannot be sep‐
arated from the hydraulic unit.
❑ Removing and installing
⇒ page 51
2 - Hydraulic units for the ABS.
- N55-
On vehicles fitted with hydraul‐
ic servo brake or hill start assist
the control unit cannot be sep‐
arated from the hydraulic unit.
❑ Removing and installing
⇒ page 51
3 - Brake line
❑ From primary piston cir‐
cuit of brake master cyl‐
inder to hydraulic unit.
❑ Specifications: 6.5 mm
and long threaded pipe
bolt M 12 x 1
4 - Brake line
❑ From secondary piston
circuit of brake master
cylinder to hydraulic
unit.
❑ Specifications: 6.5 mm
and long threaded pipe
bolt M 12 x 1
5 - Brake line
❑ To the front left brake
calliper
❑ Identification: ∅ 5.25 mm and union nut with short thread M12 x 1.
6 - Brake line
❑ To the front right brake calliper
❑ Identification: ∅ 5.25 mm and union nut with thread M10 x 1
7 - Brake line
❑ To the rear left brake calliper
❑ Identification: ∅ 5.25Protected
mm and unionCopying
by copyright. nut with short
for private thread M12
or commercial x 1.
purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
8 - Brake line respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ To the rear right brake calliper

❑ Identification: ∅ 5.25 mm and union nut with thread M10 x 1
9 - Torx screw 5.5 Nm
❑ Use new bolts.
10 - Bracket
11 - Hexagon bolt, 8 Nm
12 - Seal
❑ For brake servo.
13 - Brake servo
❑ In petrol engines the vacuum required is taken from the intake manifold.

6. Hydraulic unit, brake servo/brake master cylinder: Assembly overview 49

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

❑ Some vehicles with petrol engines and automatic gearboxes are fitted with a brake vacuum pump - V192-
⇒ page 176
❑ Vehicles with reinforced hydraulic servo brake (HBV) are fitted with a servo brake vacuum sender - G483-
⇒ Item 15 (page 50)
❑ In diesel engines the vacuum is obtained by a fitted vacuum pump ⇒ page 173
❑ Functional check:
– With engine off, press the brake pedal hard several times (this reduces the existing vacuum in the servo
brake).

– Next, keep the brake pedal depressed halfway and start engine. If the brake servo is working correctly
the brake pedal will give way notably (the brake servo effect is beginning)
❑ If faulty, renew as a complete unit.
❑ Removing and installing ⇒ page 179
14 - Sealing ring
15 - Servo brake vacuum sender - G483-
❑ Only on vehicles equipped with HBV
❑ Removing and installing ⇒ page 33
16 - Brake master cylinder
❑ Allocation: ⇒ Parts catalogue
❑ Cannot be repaired. If faulty, renew as a complete unit.
❑ Removing and installing ⇒ page 177
❑ After week 45/05 the brake light switch - F- is fitted on the brake master cylinder
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
17permitted
- Heatunless
shield
authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
18 - Hexagon nut, 25 Nm
❑ Replace after each removal
19 - Seal cap
❑ Moisten with brake fluid and place the brake fluid reservoir under pressure
20 - Brake fluid reservoir
21 - Plug
22 - Seal cap
❑ Vacuum hose connection
23 - Vacuum hose
❑ Fit in brake servo.

6.3.1 Connection of the tandem master cylin‐

der brake lines to the hydraulic unit
On the tandem master cylinder:
A - Master brake cylinder/pressure-bar piston circuit to hydraulic
unit.
- Identification: ∅ 6.5 mm and threaded pipe bolt M 12 x 1
B - From master brake cylinder/floating piston circuit to hydraulic
unit.
- Identification: ∅ 6.5 mm and threaded pipe bolt M 12 x 1
1 - Hydraulic unit to front left brake calliper.
3 - Hydraulic unit to rear right brake calliper.
4 - Hydraulic unit to rear left brake calliper.

50 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

On the hydraulic unit:

A - From hydraulic unit to master brake cylinder/pressure-bar pis‐
ton circuit.
- Specifications: ∅ 6.5 mm and long threaded pipe bolt M 12 x 1
B - From hydraulic unit to master brake cylinder/floating piston
circuit.
- Specifications: ∅ 6.5 mm and long threaded pipe bolt M 12 x 1
1 - Hydraulic unit to front left brake calliper.
- Identification: ∅ 5.25 mm and union nut with short thread M12
x 1.
2 - Hydraulic unit to front right brake calliper.
- Identification: ∅ 5.25 mm and union nut with thread M10 x 1
3 - Hydraulic unit to rear right brake calliper.
- Identification: ∅ 5.25 mm and union nut with thread M10 x 1
4 - Hydraulic unit to rear left brake calliper.
- Identification: ∅ 5.25 mm and union nut with short thread M12
x 1.

6.3.2 ABS control unit - J104- and ABS control

unit and ABS hydraulic unit - N55 - : re‐
moval.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Special tools and workshop
respect equipment
to the correctness required
of information in this document. Copyright by SEAT S.A.

♦ Torque wrench kit - SAT 8010-

♦ Brake pedal depressor - V.A.G 1869/2-

6. Hydraulic unit, brake servo/brake master cylinder: Assembly overview 51

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

♦ Calliper set for repairs; part number according to ⇒ Parts

catalogue

1 - Valve dome transport protection (rubber foam).

WARNING

The brake lines should not be folded or kinked in area of the

hydraulic unit

2.0l diesel engine:

– Remove the connection tube between the intake hose and the
exhaust gas turbocharger.

52 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Remove upper notched belt guard.

Diesel engines with particle filter:
– Unbolt the exhaust gas pressure sensor 1, - G450 - disconnect
electrical connections and unbolt and lower particulate filter ⇒
Front section of exhaust pipe with particulate filter: Assembly
overview; Rep. gr. 26 :
All vehicles (continued):
– Disengage the control unit connector in the direction shown
on the arrow -1- and remove -2-.
– Fit the block for the brake pedal - VAG 1869/2- .
– Plug the hose of the air bleeding bottle to the vent valve of the
brake calliper in the front and back left and open the vent valve.
– Operate the brake pedal using the brake pedal block - VAG
1869/2- 60 mm minimum.
– Close the front and rear left bleeding screws.
– Do not remove the block for the brake pedal - VAG 1869/2- .
– Place a sufficiently large lint-free cloth under the control unit
and the hydraulic unit.
Make sure that brake fluid does not fall onto the connectors.

– Mark both brake master cylinder brake lines -A and B- before

unscrewing them from the hydraulic unit.
– Immediately cover the brake lines and the threaded openings
with the plugs from the repair kit ⇒ Spare parts catalogue .
– Mark the brake lines (brake calliper) -1 to 4 -, unscrew and
plug.
– Pull the hydraulic unit with the control unit upwards to remove
the shock
Protected absorbers.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

6.3.3 Unscrew the ABS control unit - J104-

from the ABS hydraulic unit - N55-

Note

On vehicles fitted with hydraulic servo brake or hill start assist the
control unit cannot be separated from the hydraulic unit.

– Place the ABS control unit - J104- with the ABS hydraulic unit
- N55- downward on a clean and flat surface.

6. Hydraulic unit, brake servo/brake master cylinder: Assembly overview 53

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Undo the Torx E 5 bolts -arrows- of the hydraulic unit.

WARNING

Hydraulic pump is not to be separated from hydraulic unit.

Avoid electrostatic discharge!

– To do so, the hydraulic pump must be secured using the red

support -1- from the spare set and two threaded plugs -2- to
the anti-lock brake system (ABS) hydraulic unit - N55- .

– Carefully pull the ABS hydraulic unit - N55- with the hydraulic
pump upwards in order to separate them from the ABS control
unit - J104- along the line of separation -1-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

When removing the ABS control unit - J104- from the hydraulic
unit of the anti-lock braking system (ABS), - N55 - both must be
positioned completely parallel to each other. Otherwise the valves
may catch in the solenoid coil of the control unit.
Adapter position -2- for pump motor.
– Cover the control unit solenoids with a lint-free cloth.
After separating the control unit from the hydraulic unit, cover the
valves with the transport protection.

6.3.4 Fitting a new control unit - J104-

WARNING

Sharp movements (for example, dropping or knocking) may

destroy the control unit. The control unit is useless and must
not be used!

54 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

♦ Before fitting the new control unit, it is necessary to first fit the
pump motor adapter as far as possible and engage. Do not
damage the adapter guide.
♦ The adapter supplied as a spare part for the control unit can
only be fitted once and then it is not possible to remove it again.
♦ The white insulating compound used as a base for the control
unit acts as a seal and can not be removed.
♦ All the contact surfaces of the adapter, the pressure sensor
and the control unit, in addition to the silicone and the sealing
compound must not come into contact with hands or other ob‐
jects, nor should they be allowed to get dirty otherwise they
may be damaged.
– Press the adapter as far as possible onto the adapter guide,
until it is heard to click into position
– Fit the ABS control unit - J104- to the ABS hydraulic unit - N55-
ensuring this is straight.
– Attach the control unit for the ABS - J104- using new Torx bolts
supplied to the hydraulic unit of the anti-lock braking system
(ABS) - N55- .

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ The same hydraulic unit should
permitted not
unless be fitted
authorised withS.A.
by SEAT a SEAT
newS.A
control
does not guarantee or accept any liability with
unit more than twice, otherwise
respectthe elastic
to the seal
correctness will not provide
of information in this document. Copyright by SEAT S.A.
a suitable seal.
♦ A control unit which has been fitted previously should not be
fitted again.

6.3.5 ABS control unit - J104- and ABS hy‐

draulic unit - N55 - : installation

Note

♦ Do not remove the anti-humidity plugs until fitting the corre‐

sponding brake lines.
♦ If the plugs are removed from the control unit beforehand,
brake fluid may leak out, and therefore the fluid level and
bleeding will be incorrect.

– Install in reverse order.

– Remove the block for the brake pedal - VAG 1869/2- .
– Bleeding air from the brake system ⇒ page 163 .
– Code radio.
– Code the ABS control unit - J104- ⇒ Vehicle diagnostic tester.
During this process a basic adjustment is made to the steering
wheel angle sender - G85 - , to the transversal acceleration send‐
er - G200- and the braking pressure sender -1- - G201 - .
Specified torques:
Control unit to hydraulic unit 5.5 Nm
♦ Use new bolts!

Hexagon bolt of hydraulic unit to bracket 8 Nm

Brake lines to ABS group:
Thread M10 x 1 14 Nm

6. Hydraulic unit, brake servo/brake master cylinder: Assembly overview 55

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

Specified torques:
Thread M12 x 1 14 Nm

6.4 ABS Mark 60 -ABS/EDS/ASR/ESP/RKA+/EBA/DSR- (from week 22.08)

1 - ABS control unit - J104-

❑ Removing and installing
⇒ page 58
2 - Hydraulic units for the ABS.
- N55-
❑ Removing and installing
⇒ page 58
3 - Brake line
❑ From primary piston cir‐
cuit of brake master cyl‐
inder to hydraulic unit.
❑ Specifications: 6.5 mm
and long threaded pipe
bolt M 12 x 1
4 - Brake line
❑ From secondary piston
circuit of brake master
cylinder to hydraulic
unit.
❑ Specifications: 6.5 mm
and long threaded pipe
bolt M 12 x 1
5 - Brake line
❑ To the front left brake
calliper Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Identification: ∅ respect to the correctness of information in this document. Copyright by SEAT S.A.
5.25 mm and union nut
with short thread M10 x
1.
6 - Brake line
❑ To the front right brake
calliper
❑ Identification: ∅ 5.25
mm and union nut with
thread M10 x 1
7 - Brake line
❑ To the rear left brake calliper
❑ Identification: ∅ 5.25 mm and union nut with short thread M12 x 1.
8 - Brake line
❑ To the rear right brake calliper
❑ Identification: ∅ 5.25 mm and union nut with thread M10 x 1
9 - Torx screw 5.5 Nm
❑ Use new bolts.
10 - Bracket
11 - Hexagon bolt, 8 Nm
12 - Seal
❑ For brake servo.

56 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

13 - Brake servo
❑ In petrol engines the vacuum required is taken from the intake manifold.
❑ Some vehicles with petrol engines and automatic gearboxes are fitted with a brake vacuum pump - V192-
⇒ page 176
❑ Vehicles with reinforced hydraulic servo brake (HBV) are fitted with a servo brake vacuum sender - G483-
⇒ Item 15 (page 57)
❑ In diesel engines the vacuum is obtained by a fitted vacuum pump ⇒ page 173
❑ Functional check:
– With engine off, press the brake pedal hard several times (this reduces the existing vacuum in the servo
brake).
– Next, keep the brake pedal depressed halfway and start engine. If the brake servo is working correctly
the brake pedal will give way notably (the brake servo effect is beginning)
❑ If faulty, renew as a complete unit.
❑ Removing and installing ⇒ page 179
14 - Sealing ring
15 - Servo brake vacuum sender - G483-
❑ Only on vehicles equipped with HBV
❑ Removing and installing ⇒ page 33
16 - Brake master cylinder
❑ Allocation: ⇒ Parts catalogue
❑ Cannot be repaired. If faulty, renew as a complete unit.
❑ Removing and installing ⇒ page 177
17 - Heat shield
18 - Hexagon nut, 25 Nm
❑ Replace after each removal
19 - Seal cap
❑ Moisten with brake fluid and place the brake fluid reservoir under pressure
20 - Brake fluid reservoir
21 - Plug
22 - Seal cap
❑ Vacuum hose connection
23 - Vacuum hose
❑ Fit in brake servo.

6. Hydraulic unit, brake servo/brake master cylinder: Assembly overview 57

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

6.4.1 Connection of the tandem master cylin‐

On the hydraulic unit:

A - From hydraulic unit to master brake cylinder/pressure-bar pis‐
ton circuit.
- Specifications: ∅ 6.5 mm and long threaded pipe bolt M 12 x 1
B - From hydraulic unit to master brake cylinder/floating piston
circuit.
- Specifications: ∅ 6.5 mm and long threaded pipe bolt M 12 x 1
1 - Hydraulic unit to front left brake calliper.
- Identification: ∅ 5.25 mm and union nut with short thread M10
x 1.
2 - Hydraulic unit to front right brake calliper.
- Identification: ∅ 5.25 mm and union nut with thread M10 x 1
3 - Hydraulic unit to rear right brake calliper.
- Identification: ∅ 5.25 mm and union nut with thread M10 x 1
4 - Hydraulic unit to rear left brake calliper.
- Identification: ∅ 5.25 mm and union nut with short thread M12
x 1.

6.4.2 ABS control unit - J104- and ABS control

unit and ABS hydraulic unit - N55 - : re‐
moval.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Special tools and workshop equipment required
♦ Torque wrench kit - SAT 8010-

58 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

♦ Brake pedal depressor - V.A.G 1869/2-

♦ Calliper set for repairs; part number according to ⇒ Parts

catalogue

1 - Valve dome transport protection (rubber foam).

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
2 - Caps M10 forpermitted
brakeunless
lines and screw
authorised by SEATholes.
S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
3 - Caps M12 for brake lines and screw holes.
After removing the control unit of the hydraulic unit, the transpor‐
tation protection for the hydraulic unit valve stems must always
be applied.
No guarantee is given for hydraulic units without transport pro‐
tection.
Removing
Location:
The control unit is bolted to the hydraulic unit and is located on
the right side of the engine compartment.

WARNING

The brake lines should not be folded or kinked in area of the

hydraulic unit

– Check and note the code for the control unit fitted.
– Note or request radio code on vehicles with coded radio if
necessary.

6. Hydraulic unit, brake servo/brake master cylinder: Assembly overview 59

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Disconnecting the battery ⇒ Electrical system; Rep. gr. 27 ;

Disconnecting and connecting battery
– Remove engine cover
1.4 litre TSI engine:
– Remove the pressure hose and intake sleeve along with the
throttle valve module ⇒ 4 cylinder Injection engine (1.4 l Direct
injection valve, turbocharger and rotary piston compressor);
Rep. gr. 24 ; Injection system; Part I Intake manifold - As‐
sembly overview .
– Remove the air filter housing ⇒ 4 cylinder. Injection engine
(1.4 l Direct injection valve, turbocharger and rotary piston
compressor); Rep. gr. 21 ; Supercharger air system .
– Loosen and remove the coolant hose from coolant expansion
tank.
1.9 l diesel engine:
– Loosen the connecting hose on the intake support ⇒ 4 cylinder
Diesel (2 valve); Rep. gr. 21 ; Charged air system with exhaust
gas turbocharger .
– Remove the intake manifold flap motor V157 ⇒ 4-cylinder
diesel (2 valves); Rep. gr. 23 ; mixture preparation, injection .
2.0l diesel engine:
– Remove the connection tube between the intake hose and the
exhaust gas turbocharger.
– Remove upper notched belt guard.
Diesel engines with particle filter:
– Unbolt the exhaust gas pressure sensor 1, - G450 - disconnect
electrical connections and unbolt and lower particulate filter ⇒
Front section of exhaust pipe with particulate filter: Assembly
overview; Rep. gr. 26 :
All vehicles (continued):
– Disengage the control unit connector in the direction shown
on the arrow -1- and remove -2-.
– Fit the block for the brake pedal - VAG 1869/2- .
– Plug the hose of the air bleeding bottle to the vent valve of the
brake calliper in the front and back left and open the vent valve.
– Operate the brake pedal using the brake pedal block - VAG
1869/2- 60 mm minimum.
– Close the front and rear left bleeding screws.
– Do not remove the block for the brake pedal - VAG 1869/2- .
– Place a sufficiently large lint-free cloth under the control unit
and the hydraulic unit.
Make sure that brake fluid does not fall onto the connectors.

60 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Mark both brake master cylinder brake lines -A and B- before

6.4.3 Unscrew the ABS control unit - J104-

from the ABS hydraulic unit - N55-

Note

– Place the hydraulic unit and the control unit facing

Protected by downwards
copyright. Copying for private or commercial purposes, in part or in whole, is not
on a flat, clean surface. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Unscrew the Torx screws of the control unit.
– Remove the control unit from the hydraulic unit -arrow- in a
perpendicular direction, without turning.
– Carefully remove all the seals to the hydraulic unit valve stems.

WARNING

♦ When the control unit has been removed, the printed cir‐
cuit board is visible.
♦ Do not allow dirt or damp to enter the control unit.
♦ Avoid electrostatic discharge!

– Cover the control unit solenoids with a lint-free cloth.

After disconnecting control unit and hydraulic unit, fit transporta‐
tion protection for valve domes.

6.4.4 Fitting a new control unit - J104-

WARNING

Severe shocks (e.g. falling or jolts) can damage the control

unit. The control unit is useless and must not be used!

• Clean the surfaces before fitting.

6. Hydraulic unit, brake servo/brake master cylinder: Assembly overview 61

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Insert the seals -A- a little way into the valve stems.
– Place the control unit in the hydraulic unit taking care not to tilt
it.
This pushes the seals into their final position.
– Using the Torx screws provided, tighten the hydraulic unit and
the control unit diagonally to the respective tightening torque
in stages.

Note

6.4.5 ABS control unit - J104- and ABS hy‐

draulic unit - N55 - : installation

Note

♦ Do not remove the anti-humidity plugs until fitting the corre‐

sponding brake lines.
♦ If the plugs are removed from the control unit beforehand,
brake fluid may leak out, and therefore the fluid level and
bleeding will be incorrect.

– Install in reverse order.

WARNING

When installing the bracket, ensure that the rubber dampers

are not pressed out of the console. Following installation,
check that the hydraulic unit is mounted correctly with the con‐
trol unit in order to avoid malfunctions.

– Remove the block for the brake pedal - VAG 1869/2- .

– Bleeding air from the brake system ⇒ page 163 .
– Code radio.
– Code the ABS control unit - J104- ⇒ Vehicle diagnostic tester.
During this process a basic adjustment is made to the steering
wheel angle sender - G85 - , to the transversal acceleration send‐
er - G200- and the braking pressure sender -1- - G201 - .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Specified torques:
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Control unit to hydraulic unit 2 Nm +
♦ Use new bolts! 0.8 Nm

Hexagon bolt of hydraulic unit to bracket 8 Nm

Brake lines to ABS group:
Thread M10 x 1 14 Nm
Thread M12 x 1 14 Nm

62 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

7 ABS components on the front axle:

assembly overview
⇒ “7.1 Removing and installing speed sensor on front axle”, page
63

1 - Spherical head bolt ⇒ Run‐

ning gear, axles, steering;
Rep. gr. 40 ; Front wheel sus‐
pension
2 - Wheel bearing housing
3 - Speed sensor
❑ Removing and installing
⇒ page 63
❑ Before fitting the sensor,
clean the inner surface
of the hole and apply
solid lubricant paste ⇒
Parts catalogue .
4 - Allen screw, 8 Nm
5 - Mounting
❑ Removing and fitting ⇒
Running gear, axles,
steering; Rep. gr. 40 ;
Front wheel suspension
6 - Splash plate
7 - Bolt, 10 Nm
8 - Brake disc
❑ Allocation ⇒ page 1
9 - Star bolt -4 Nm

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
7.1 Removing and installing speed sensor
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
on front axle

7.1.1 Removing
– Raise the vehicle.

7. ABS components on the front axle: assembly overview 63

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Release and remove the connector -1- of the speed sensor.

– Unscrew and extract the bolt -1- .

– Extract the speed sensor -2- from the sleeve.

7.1.2 Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:
– Before fitting the speed sender, clean the inner surface of the
hole and apply solid lubricant paste ⇒ Spare parts catalogue
– Turn steering wheel fully in both directions and check that rev.
sensor cable is able to move freely.

64 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

8 ABS system components in rear axle:

⇒ “8.1 ABS components on the rear axle (front-wheel drive): As‐
sembly overview”, page 65
⇒ “8.2 ABS components on the rear axle (4-wheel drive): Assem‐
bly overview”, page 66

8.1 ABS components on the rear axle (front-

wheel drive): Assembly overview
⇒ “8.1.1 speed sensor on the rear axle (front-wheel drive): instal‐
lation and removal”, page 65
Vehicles with front-wheel drive

1 - Allen screw, 8 Nm
2 - Speed sensor
❑ Removing and installing
⇒ page 65
❑ Before fitting the speed
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
sensor, clean
respectthe
to theinner
correctness of information in this document. Copyright by SEAT S.A.
surface of the hole and
apply solid lubricant
paste ⇒ Parts catalogue
3 - Wheel bracket
4 - Mounting
❑ ⇒ Running gear, axles,
steering; Rep. gr. 42 ;
Front wheel suspension
5 - Bolt XZN
❑ Tightening torque: ⇒
Running gear, axles,
steering; Rep. gr. 42 ;
Rear wheel suspension
6 - Dustcap
❑ Removing and fitting ⇒
Running gear, axles,
steering; Rep. gr. 42 ;
Rear wheel suspension
7 - Brake disc
❑ Allocation ⇒ page 1
8 - Star bolt -4 Nm
9 - Bolt, 60 Nm
10 - Splash plate

8.1.1 speed sensor on the rear axle (front-

wheel drive): installation and removal
Removing
– Raise the vehicle.

8. ABS system components in rear axle: 65

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Release and remove the connector -1- of the speed sensor.

– Unscrew the bolt -1- and remove the speed sensor from the
axle support.
Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:
– Before fitting the speed sensor, clean the inner surface of the
hole and apply solid lubricant paste ⇒ Parts catalogue

8.2 ABS components on the rear axle (4-

wheel
Protected by drive):
copyright. Copying Assembly
for private overview
or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
⇒ “8.2.1 Speed
respect to sensor on the
the correctness rear axle
of information in this(4-wheel drive):
document. Copyright by installa‐
SEAT S.A.
tion and removal”, page 67
Vehicles with four wheel drive

66 Rep. gr.45 - Anti-lock brake system

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

1 - ABS rev. sensor

❑ Before inserting sensor,
clean interior of the hole
and apply heat resistant
paste to the bolts ⇒
Spare parts catalogue
❑ Removing and installing
⇒ page 65
2 - Allen screw, 8 Nm
3 - Wheel hub with wheel bear‐
ing
❑ The ABS sensor ring is
fitted in the wheel bear‐
ing

8.2.1 Speed sensor on the rear axle (4-wheel

drive): installation and removal
Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Raise the vehicle. respect to the correctness of information in this document. Copyright by SEAT S.A.

– Disconnect connector -1- from revolutions sensor cable.

– Undo the bolt -2- on steering knuckle.
– Remove the ABS revolution sensor from the steering knuckle.
Installing
– Before inserting revolution sensor, clean interior of the hole
and apply heat resistant paste to the bolts ⇒ Spare parts
catalogue around the sensor
– Insert revolution sensor in opening in the steering knuckle and
tighten bolt to 8 Nm.
– Connect speed sensor to speed sensor wire.

8. ABS system components in rear axle: 67

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

46 – Brakes - mechanism
1 Front wheel brake: repairs

Note

♦ To suck the liquid from the brake fluid tank, use the brake
bleeder - SAT 1175B-
♦ Before removing the brake callipers, or the hose, apply the
brake pedal lock - V.A.G 1869/2- so that the brake fluid tank
does not empty.

WARNING
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
After fitting the brake pads,
respect operate ofthe
to the correctness brakein this
information pedal strongly
document. Copyright by SEAT S.A.
with the vehicle stopped so that the brake pads adopt the po‐
sition corresponding to normal operation.

1.1 FS 3 front wheel brake: component

overview
General indications ⇒ page 68 .

68 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

1 - Bolt, 10 Nm
2 - Brake disc
❑ Allocation, measure‐
ments, wear limits
⇒ page 1
❑ To remove, extract the
brake calliper.
❑ Do not separate the
brake disks from the
wheel hubs by force. If
necessary, use an oxide
solvent; otherwise the
brake disks may be
damaged.
❑ Always replace by axles
3 - Star bolt -4 Nm
4 - Brake pads
❑ Brake pad thickness,
wear limit ⇒ page 4
❑ With or without brake
pad wear sender de‐
pending on the version
⇒ Electronic parts cata‐
logue
❑ Check the thickness of
the pads: ⇒ Mainte‐
nance ; Booklet 1
❑ Removing and installing
⇒ page 71
❑ Note correct installation

1. Front wheel brake: repairs 69

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

position ⇒ page 70
❑ Always replace by axles
5 - Connector, depending on the version
❑ When changing the pads, remove the bracket ⇒ Item 13 (page 70)
6 - Brake caliper
❑ Piston diameter ⇒ page 4
❑ Removing and installing ⇒ page 74
❑ Repairs ⇒ page 144
7 - Guide pin, 28 Nm
8 - Plug
9 - Brake hose with banjo union and banjo bolt, 35 Nm
❑ Anti-twist protection
10 - Guide pin, 30 Nm
11 - Plug
12 - Panel bolt
13 - Bracket
14 - Wheel bearing housing
15 - Speed sensor
❑ Removing and installing ⇒ page 63
❑ Before fitting the sensor,
Protected clean
by copyright. theforinner
Copying private surface ofpurposes,
or commercial the hole and
in part or inapply
whole, issolid
not lubricant paste ⇒ Parts
catalogue .
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

16 - Hexagon socket head bolt

❑ Tightening torque ⇒ Item 4 (page 63)
17 - Bearing with integrated rotor
❑ Removing and fitting ⇒ Running gear, axles, steering; Rep. gr. 40 ; Front wheel suspension
18 - Splash plate

Installation location of the brake pads

♦ Pad with large, three finger bracket -1- towards the piston side.
♦ Pad with small, three finger bracket -2- (black) towards the
exterior of the brake calliper.

70 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

Brake hose connection with anti-twist protection

Ensure that the groove in the ring tube of the hose is adjusted to
the locking projection -arrow-.

1.2 FS 3 front wheel brake: brake pads in‐

stallation and removal
Special tools and workshop equipment required
♦ Torque wrench kit - SAT 8010-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

♦ Thrust piece - T10145-

1.2.1 Removing

Note

If the brake pads are to be re-used, before removing them from

the brake carrier, mark their positions for posterior fitting. Put them
back in the same positions, otherwise, the braking effect will not
be even.

– Extract the bolts from the front wheels.

1. Front wheel brake: repairs 71

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Release and disconnect the connector -1- from the left hand
side, for the wear indication of the brake pads.

– Extract the protection plugs and the guide pins -arrows- se‐
curing the callipers, on the brake plate.
– Remove brake caliper and secure with wire so that weight of
brake caliper does not strain or damage brake hose.

Note

♦ Do not twist or bend the brake hose.

– Remove the brake pads from the brake plate.

Cleanliness:

WARNING

Never clean the brake system with compressed air; harmful

dust particles will be released.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Only alcohol may be used to clean the brake calliper housing.
– Thoroughly clean the brake plate and brake calliper using a
lint free cloth in the brake pad contact areas and remove cor‐
rosion.

1.2.2 Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:

72 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

Before pressing piston back into cylinder with piston resetting tool,
draw off brake fluid from brake fluid reservoir. Otherwise, partic‐
ularly if reservoir has been topped up, fluid will overflow and cause
damage.
– Press in the piston with the press tool - T10145- .

Note

♦ Before fitting new brake pads, press the piston inside the cyl‐
inder with the press tool - T10145- .
♦ If brake fluid has been added, before retracting the piston to‐
wards the interior of the cylinder, a part of the liquid must be
sucked from the brake fluid tank, use the brake bleeder - SAT
1175B- . Otherwise brake fluid may spill out causing damage
to the bodywork.

WARNING

Brake fluid is toxic and should never be sucked by mouth using

a flexible tube.

• Brake pads: assembly location:

– Pad with large, three finger bracket -1-S.A

towards the piston side.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Pad with small, three finger bracket -2- (black) towards the
exterior of the brake calliper.
– Beginning from the lower part, fit the brake calliper into the
casing, with the pads fitted in place.

• The pin -arrow- of the brake calliper casing should be behind

wheel bearing casing guide.

1. Front wheel brake: repairs 73

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Screw in the brake calliper to the brake plate with the two guide
pins -arrows-. Tightening torque ⇒ Item 7 (page 70) .
– Fit the two protective covers.
– Insert the plug connector for the brake pad wear indicator.
– Fit wheels.
Tightening torque for wheel bolts ⇒ Rep. gr. 44

WARNING

After fitting the brake pads, operate the brake pedal strongly
with the vehicle stopped so that the brake pads adopt the po‐
sition corresponding to normal operation.

– Check the brake fluid level and refill in case of doubt.

1.3 FS 3 front wheel brake: brake calliper

installation and removal
Special tools and workshop equipment required
♦ Torque wrench kit - SAT 8010-

♦ Brake pedal depressor - V.A.G 1869/2-

1.3.1 Removing
– Remove the brake pads ⇒ page 71 .

74 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Fit the brake pedal lock - V.A.G 1869/2- between the brake
pedal and the driver's seat. Push the brake pedal by at least
60 mm.

Note

Thus the master cylinder valves close and the brake fluid tank
does not empty.

– Connect the hose of the collecting bottle - SAT 1175B/1- on

the bleeder bolt of the removed brake callipers.
– Open the bleeding bolt.
– Do not remove the block for the brake pedal - V.A.G 1869/2- .
– Unscrew and extract the brake calliper, along with the hollow
bolt, the hose and the ring tube.
If the brake pads are to be re-used, before removing them from
the brake carrier, mark their positions for posterior fitting. Put them
back in the same positions, otherwise, the braking effect will not
be even.

1.3.2 Installing
Carry out installation in the reverse sequence, noting the follow‐
ing: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Fit the brake pads ⇒ page 72 .
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Bleeding air from the brake system ⇒ page 163 .

1.4 Front brakes FN 3: component overview

General indications ⇒ page 68 .

1. Front wheel brake: repairs 75

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

1 - Bolt, 10 Nm
2 - Brake disc
❑ Allocation, measure‐
ments, wear limits
⇒ page 1
❑ To remove, extract the
brake calliper, along
with the hollow bolt, the
hose and the ring tube.
❑ Do not separate the
brake disks from the
wheel hubs by force. If
necessary, use an oxide
solvent; otherwise the
brake disks may be
damaged.
❑ Always replace by axles
3 - Star bolt -4 Nm
4 - Brake pads
❑ Brake pad thickness,
wear limit ⇒ page 4
❑ With or without brake
pad wear sender de‐
pending on the version
⇒ Electronic parts cata‐
logue
❑ Check the thickness of
the pads: ⇒ Mainte‐
nance ; Booklet 1
❑ Removing and installing
⇒ page 78
❑ Note correct installation

76 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

position ⇒ page 78
❑ Always replace by axles
5 - Retaining spring
❑ Insert into the two holes in the brake calliper housing
6 - Brake carrier
❑ Supplied as genuine part, assembled with sufficient grease on guide pins.
❑ In case of damage to the protection hoods, fit the repair kit, use the grease pad supplied to grease the
guide pins
7 - Housing for brake calliper
❑ Piston diameter ⇒ page 4
❑ Different versions ⇒ Parts catalogue
❑ Unscrew from brake carrier to replace brake pads
❑ Removing and installing ⇒ page 82
❑ Repairs ⇒ page 82
8 - Guide pin, 30 Nm
9 - Plug Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
10 - Brake hose with banjo union and banjo bolt, 35 Nm
respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ Anti-twist protection ⇒ page 78

11 - Guide pin, 30 Nm
12 - Plug
13 - Panel bolt
14 - Bracket
15 - Ribbed bolt 190 Nm
❑ Clean ribs if using again
16 - Wheel bearing housing
17 - Speed sensor
❑ Removing and installing ⇒ page 63
❑ Before fitting the sensor, clean the inner surface of the hole and apply solid lubricant paste ⇒ Parts
catalogue .
18 - Hexagon socket head bolt
❑ Tightening torque ⇒ Item 4 (page 63)
19 - Bearing with integrated rotor
❑ Removing and fitting ⇒ Running gear, axles, steering; Rep. gr. 40 ; Front wheel suspension
20 - Splash plate

1. Front wheel brake: repairs 77

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

Installation location of the brake pads

♦ Pad with no bracket -1- towards the exterior side of the calliper.
♦ Pad with large, three finger bracket -2- towards the piston side.

Brake hose connection with anti-twist protection

– Ensure that the groove in the ring tube of the hose is adjusted
to the locking projection -arrow-.

1.5 Front brakes FN 3: brake pads installa‐

tion and removal
Special tools and workshop equipment required
♦ Torque wrench kit - SAT 8010-

78 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

♦ Thrust piece - T10145-

1.5.1 Removing

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
If the brake pads are to be re-used, before removing them from
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
the brake carrier, mark their positions for posterior fitting. Put them
respect to the correctness of information in this document. Copyright by SEAT S.A.

back in the same positions, otherwise, the braking effect will not
be even.

– Extract the bolts from the front wheels.

– Release and disconnect the connector -1- from the left hand
side, for the wear indication of the brake pads.

– Remove the retainer spring for the brake pads from the calliper
housing using a screwdriver as a lever -arrow- and remove it.

1. Front wheel brake: repairs 79

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Remove the protective caps -arrows-.

– Unscrew the guide pins -arrows-.

– Remove brake caliper and secure with wire so that weight of
brake caliper does not strain or damage brake hose.
– Take brake pad out of brake caliper or from brake carrier.

Note

♦ Do not twist or bend the brake hose.

♦ If the brake pads are to be re-used, before removing them from
the brake carrier, mark their positions for posterior fitting. Put
them back in the same positions, otherwise, the braking effect
will not be even.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove the pads from the carrier / permitted
brakes. unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Cleanliness:

WARNING

Never clean the brake system with compressed air; harmful

dust particles will be released.

Only alcohol may be used to clean the brake calliper housing.

– Thoroughly clean the brake plate and brake calliper using a
lint free cloth in the brake pad contact areas and remove cor‐
rosion.
– Clean brake caliper, in particular the bonding surface for the
brake pad. It must be free of adhesive and grease residues.

1.5.2 Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:

80 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Press in the piston with the press tool - T10145- .

Note

WARNING

Brake fluid is toxic and should never be sucked by mouth using

a flexible tube.

• Brake pads: assembly location:

1 - Pad with large, three finger bracket -2- towards the piston side.
2 - Pad with no bracket -1- towards the exterior side of the calliper.

– Fit outer brake pad to brake carrier.

– Pull protective foil off outer brake pad backplate.
– Insert inner brake pad with retaining spring into brake caliper
(piston).

Note

♦ When positioning the brake caliper, ensure that the brake pad
does not stick to the brake caliper housing before it is posi‐
tioned correctly.
♦ Do not damage adhesive surface.

1. Front wheel brake: repairs 81

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Screw in the brake calliper to the brake plate with the two guide
pins -arrows-. Tightening torque ⇒ Item 8 (page 77) .
– Fit the two protective covers.

– Fit the retention spring -arrow- to the calliper housing.

WARNING

♦ Insert the retainer spring under the brake carrier once it

has been inserted into the two holes. If this is incorrectly
fitted then the wear on the outer pad cannot be corrected,
this will gradually extend the pedal stroke.
♦ After fitting the brake pads, operate the brake pedal
strongly with the vehicle stopped so that the brake pads
adopt the position corresponding to normal operation.

– If present, attach the plug connector for the brake pad wear
indicator. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Fit wheels. respect to the correctness of information in this document. Copyright by SEAT S.A.

Note

After every brake pad change, depress brake pedal firmly several
times with vehicle stationary, so that brake pads are properly
seated in their normal operating position.

– Check the brake fluid level and refill in case of doubt.

1.6 Front brakes FN 3: Brake calliper instal‐

lation and removal
Special tools and workshop equipment required
♦ Torque wrench kit - SAT 8010-

82 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

♦ Brake pedal depressor - V.A.G 1869/2-

1.6.1 Removing
– Remove the brake pads ⇒ page 78 .
– Fit the brake pedal lock - V.A.G 1869/2- between the brake
pedal and the driver's seat. Push the brake pedal by at least
60 mm.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Note permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Thus the master cylinder valves close and the brake fluid tank
does not empty.

– Connect the hose of the collecting bottle - SAT 1175B/1- on

the bleeder bolt of the removed brakepads.
– Open the bleeding bolt.
– Do not remove the block for the brake pedal - V.A.G 1869/2- .
– Unscrew and extract the brake calliper, along with the hollow
bolt, the hose and the ring tube.

1. Front wheel brake: repairs 83

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

1.6.2 Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:
Brake hose connection with anti-twist protection
– Ensure that the groove in the ring tube of the hose is adjusted
to the locking projection -arrow-.
– Screw brake hose on brake calliper tightening torque
⇒ Item 10 (page 77) .
– Remove brake pedal depressor - V.A.G 1869/2- .
– Fit the brake pads ⇒ page 80 .
– Bleed brake system ⇒ page 163 .
– Fit wheels.
Tightening torque for wheel bolts ⇒ Rep. gr. 44

Note

♦ Firmly depress brake pedal several times with vehicle station‐

ary so that the brake pads are properly seated in their normal
operating position.
♦ Check brake fluid level.

1.7 FNR G Front wheel brake (Model Leon

2006 Cupra): Assembly overview
General indications ⇒ page 68 .

84 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

1 - Wheel bearing housing

2 - Speed sensor
❑ Removing and installing
⇒ page 63
❑ Before fitting the sensor,
clean the inner surface
of the hole and apply
solid lubricant paste ⇒
Parts catalogue .
3 - Hexagon socket head bolt
❑ Tightening torque
⇒ Item 4 (page 63)
4 - Bearing with integrated ro‐
tor
❑ Removing and fitting ⇒
Running gear, axles,
steering; Rep. gr. 40 ;
Front wheel suspension
5 - Splash plate
6 - Bolt, 10 Nm
7 - Brake disc
❑ Allocation, measure‐
ments, wear limits
⇒ page 1
❑ To remove, extract the
brake calliper.
❑ Do not separate the
brake disks from the
wheel hubs by force. If
necessary, use an oxide
solvent; otherwise the
brake disks may be

1. Front wheel brake: repairs 85

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

damaged.
❑ Always replace by axles
8 - Star bolt -4 Nm
9 - Elastic hook
10 - Brake pads
❑ Brake pad thickness, wear limit ⇒ page 1
❑ Different versions ⇒ Parts catalogue
❑ Check the thickness of the pads: ⇒ Maintenance ; Booklet 1
❑ Removing and installing ⇒ page 87
❑ Note correct installation position ⇒ page 87
❑ Always replace by axles
11 - Brake carrier
❑ Supplied as genuine part, assembled with sufficient grease on guide pins.
❑ In case of damage to the protection hoods, fit the repair kit, use the grease pad supplied to grease the
guide pins
12 - Retaining spring
❑ Position the ends in the brake calliper housing and insert it into the hole in the brake pad.
13 - Housing for brake calliper
❑ Piston diameter ⇒ page 4
❑ Different versions ⇒ Parts catalogue
❑ Unscrew from brake carrier to replace brake pads
❑ Removing and installing ⇒ page 82
❑ Repairs ⇒ page 82
14 - Packing plate
15 - Balancing weight
❑ In vehicles after 22/07
16 - Bolt, 10 Nm
17 - Plug
18 - Guide pin, 30 Nm
19 - Plug
20 - Bolt, 15 Nm
21 - Brake line
❑ Screw it into the brake calliper housing
❑ Connect the flexible tube of the brake by immobilising its hexagonal part.
❑ The tube must not be twisted
❑ Verify that the fixing tabs are well seated in the grooves in the support.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Brake line connection, on the brake calliper
permitted ⇒ page
unless authorised 87 S.A. SEAT S.A does not guarantee or accept any liability with
by SEAT
respect to the correctness of information in this document. Copyright by SEAT S.A.
22 - Bracket
❑ Bolt it onto the brake calliper housing
❑ For brake pipes
23 - Splined bolt
❑ Clean ribs if using again
❑ Tightening torque ⇒ page 87

86 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

Tightening torque of hexagon socket head cap screw

Note

Tightening torque of hexagon socket head cap screw in 2 stages.

1st Stage Tighten both hexagon socket head cap screw of the
brake plate with 15 Nm
2nd Stage Tighten both hexagon socket head cap screw of the
brake plate with 200 Nm

Installation location of the brake pads

♦ Pad -1- towards the exterior side of the calliper.
♦ Brake pad -2- towards the piston side.

Brake pipe connection on the brake calliper

♦ Brake hose -2-: 14 Nm
♦ Hexagonal bolt -3-: 15 Nm

1.8 FNR-G Front wheel brake (Leon 2006

Cupra model): Brake pads installation
and removal
or
Special tools and workshop equipment required
♦ Torque wrench kit - SAT 8010-

1. Front wheel brake: repairs 87

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

♦ Thrust piece - T10145-

1.8.1 Removing

Note

♦ If the brake pads are to be re-used, before removing them from

the brake carrier, mark their positions for posterior fitting. Put
them back in the same positions, otherwise, the braking effect
will not be even.
♦ To the fit the brake discs pay attention to the direction of motion
“arrow on the brake disc” and whether it is fitted on the “left or
right”.

– Raise the vehicle.

– Remove wheels.
– Remove the securing spring by carefully placing a screwdriver
between the securing spring and the brake pad spring and
using it as a lever.

Note

The spring under tension; protect your hand.

– Ensure you do not scratch or damage the surface of the brake

pad fixing spring.

88 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Be careful with the insert -arrow- for the brake pad spring.
– Remove the retainer spring for the brake pads from the calliper
housing using a screwdriver as a lever arrow and remove it.

– Remove plug connector -1- for the brake pad wear indicator.

– Remove the protective caps -1-.

– Unscrew both guide pins from the brake calliper and remove
them.
– Remove the brake calliper housing and place it so that the
weight of the brake calliper does not rest on or damage the
flexible tube of the brake.
– Remove the brake pads from the brake calliper housing.
Cleanliness:

WARNING

Never clean the brake system with compressed air; harmful

dust particles will be released.

Only alcohol may be used to clean the brake calliper housing.

– Thoroughly clean the brake plate and brake calliper using a
lint free cloth in the brake pad contact areas and remove cor‐
rosion.

1. Front wheel brake: repairs 89

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

1.8.2 Installing

Note

WARNING
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Brake fluid is toxic and
permitted should
unless never
authorised beS.A.
by SEAT sucked
SEAT S.Abydoes
mouth usingor accept any liability with
not guarantee
a flexible tube. respect to the correctness of information in this document. Copyright by SEAT S.A.

– Press in the piston with the press tool - T10145- .

Installation location of the brake pads

♦ Pad -1- towards the exterior side of the calliper.
♦ Brake pad -2- towards the piston side.

– Fit the brake pads -1- and -2- in the brake calliper.
– Fit the assembly to the brake plate.

90 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Bolt brake caliper to brake support plate with both guide pins.
Tightening torque ⇒ Item 18 (page 86) .
– Make sure the flexible tube of the brake is fitted without twists.
– Fit the two protective covers.
– Insert the plug connector for the brake pad wear indicator.

– Place the securing spring in the upper part of the housing and
in the securing tab of the brake pad -arrows-.

– Fit the lower part of the housing securing spring by pressing

evenly in the -direction of the arrow-.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

1. Front wheel brake: repairs 91

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Check that the securing spring of the housing has engaged

correctly into the brake pad attachment and that the upper and
lower arms are correctly secured to the brake back plate.
– Fit the wheels ⇒ Wheels and tyres; Rep. gr. 44 .

WARNING

After fitting the brake pads, operate the brake pedal strongly
with the vehicle stopped so that the brake pads adopt the po‐
sition corresponding to normal operation.

– Check the brake fluid level and refill in case of doubt.

1.9 FNR-G Front wheel brake (Leon 2006

Cupra model): Brake calliper installation
and removal
Special tools and workshop equipment required
♦ Torque wrench kit - SAT 8010-

♦ Brake pedal depressor - V.A.G 1869/2-

1.9.1 Removing
– Remove the brake pads ⇒ page 78 .

92 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Fit the brake pedal lock - V.A.G 1869/2- between the brake
pedal and the driver's seat. Push the brake pedal by at least
60 mm.

Note

Thus the master cylinder valves close and the brake fluid tank
does not empty.

– Connect the hose of the collecting bottle - SAT 1175B/1- on

the bleeder bolt of the removed brakepads.
– Open the bleeding bolt.
– Do not remove the block for the brake pedal - V.A.G 1869/2- .

– Remove the elastic pin -1-.

– Unscrew bolt -3-.
– Unscrew the brake fluid tubing -2- from the brake calliper and
remove the brake calliper.

1.9.2 Installing
Carry out installation in the
Protected by copyright. reverse
Copying sequence,
for private or commercialnoting the
purposes, follow‐
in part or in whole, is not
ing: permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Fit the brake pads ⇒ page 87 .

– Install brake pipe of the brake calliper ⇒ page 87
– Bleed brake system ⇒ page 163 .

1.10 FNR G Front wheel brake (Model Leon

2009 Cupra and Cupra R): Assembly
overview
General indications ⇒ page 68 .

1. Front wheel brake: repairs 93

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

1 - Splash plate
2 - Torx screw 12 Nm
3 - Brake disc
❑ Allocation, measure‐
ments, wear limits
⇒ page 1
❑ To remove, extract the
brake calliper.
❑ Do not separate the
brake disks from the
wheel hubs by force. If
necessary, use an oxide
solvent; otherwise the
brake disks may be
damaged.
❑ Always replace by axles
4 - Torx screw 4 Nm
5 - Ribbed bolt 200 Nm
❑ Clean the screw when
using again
6 - Brake carrier
❑ Screwed onto the wheel
bearing housing
7 - Brake pads
❑ Brake pad thickness,
wear limit ⇒ page 1
❑ With brake pad wear
sender
❑ Check the thickness of
the pads: ⇒ Mainte‐
nance ; Booklet 1
❑ Removing and installing
⇒ page 95
❑ Always replace by axles
8 - Retaining spring
❑ Attach the retaining spring on the brake calliper and then press under the brake support plate.
9 - Brake caliper
❑ Do not unscrew brake lines / brake hose when replacing brake pads
❑ Cannot be dismantled.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removingpermitted
and installing ⇒ page
unless authorised by SEAT98S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Repairs ⇒ page 149
10 - Guide sleeves
❑ Guide sleeve for the guide pins
11 - Guide pin, 30 Nm
12 - Cover cap
❑ Removing
13 - Packing plate
14 - Balancing weight
Allocation ⇒ Electronic parts catalogue (ETKA) .

94 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

15 - Bolt, 10 Nm
16 - Protective cap
17 - Brake line, 14 Nm
18 - Bolt, 15 Nm
19 - Bracket
❑ Holder for the brake line / brake hose screw connection
20 - Brake hose
21 - Allen screw, 8 Nm
22 - Bracket
23 - Elastic hook

1.11 FNR G Front wheel brake (Model Leon

2009 Cupra and Cupra R): Brake pad
installation and removal
Special tools and workshop equipment required
♦ Torque wrench kit - SAT 8010-

♦ Thrust piece - T10145-

1.11.1 Removing
If the brake pads will be reused, these have to be marked when
removing. These must be reinstalled in the same position other‐
wise an equal braking affect cannot be ensured.
– Remove front wheels.

1. Front wheel brake: repairs 95

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Lever off the retaining spring -1- from the brake calliper using
a screwdriver -2- in the -direction of the arrow B-. For this pur‐
pose, position the screwdriver between the retaining spring
and brake calliper -arrow A-.
– During this procedure, secure the retaining spring -1- of the
brake calliper with a cloth to prevent it from springing away.

– Disconnect the connector on the sensor for the brake pad wear
sender -1-.

– Remove the protective caps -arrows-.

– Unscrew both guide pins -arrows- from the brake calliper

housing and remove them.

96 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Remove the brake calliper -1- from the brake plate -2- and
hook with a piece of wire so that the weight of the calliper does
not pull on or damage the brake hose.
– Remove the outer brake pad -3- from the brake plate -2-.
– Remove the inside brake pad -4- from the brake calliper -1-.
Cleanliness:

WARNING

Never clean the brake system with compressed air; harmful

dust particles will be released.

– Thoroughly clean the brake plate in the areas of contact with

the brake pads and remove corrosion.
– Clean the brake calliper.
To clean the brake pads only methylated spirits may be used.

1.11.2 Installing
Before pressing piston back into cylinder with piston resetting tool,
draw off brake fluid from brake fluid reservoir. Otherwise, if brake
fluid has been refilled, this might leak and cause damage.
– Press in the piston with the press tool - T10145- .

– Mount the inside brake pad with the elastic part -4- to the brake
calliper (piston).
– Mount the outer brake pad -3- onto the brake plate -2-.
– Mount the brake calliper -1- onto the brake plate -2-.

1. Front wheel brake: repairs 97

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Screw the brake calliper onto the brake support plate with the
two guide pins and tighten to the respective tightening torque .
Tightening torque ⇒ Item 11 (page 94) .
– Fit the two protective covers.

– Install the retaining spring of the brake calliper -1- so that the
bottom spring support is located behind the brake calliper
-arrow A- and the centre guide pin -arrow B- behind the brake
calliper housing -3-.
– Swivel the spring support behind the brake calliper -2-
-arrow C-.
– Connect the connector to the sensor for the brake pad wear
sender.
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Specified torques of wheel bolts .

WARNING

After fitting the brake pads, operate the brake pedal strongly
with the vehicle stopped so that the brake pads adopt the po‐
sition corresponding to normal operation.

– Check the brake fluid level and refill in case of doubt.

1.12 FNR G Front wheel brake (Model Leon

2009 Cupra and Cupra R): Brake callip‐
er installation and removal
Special tools and workshop equipment required
♦ Torque wrench kit - SAT 8010-

98 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

♦ Brake pedal depressor - V.A.G 1869/2-

1.12.1 Removing
The following process is only required to replace the brake calliper
or for the repair work described below.
– Remove wheels.
– Remove retaining spring by levering with a screwdriver. For
this purpose, position the screwdriver between the retaining
spring and brake calliper -detail-.
– During this procedure, secure the retaining spring of the brake
calliper with a cloth to prevent it from springing away.

– Disconnect the connector on the sensor for the brake pad wear
sender -1-.

1. Front wheel brake: repairs 99

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Place the bleeding hose -1- of the connection bottle - SAT

1175B/1- -3- on the bleeding bleeding screw of brake calliper
-2- and open the bleeding screw.

– Fit the block for the brake pedal - V.A.G 1869/2-

– Close the bleeding valve and remove - SAT 1175B/1- remove
the bleeding bottle.

– Unscrew brake line -4- from brake hose -2-.

– Unclip the retaining clip -1- and remove the brake hose -2-
from the holder -3-.

– Remove the protective caps -arrows-.

100 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Unscrew both guide pins from the brake calliper housing and
remove them.

– Remove the brake calliper -1- from the brake plate -2-.
– Remove the inside brake pad from the brake calliper / piston.

1.12.2 Installing
• The piston is removed.
– Mount the inside brake pad with the elastic part -1- to the brake
calliper / piston -2-.

1. Front wheel brake: repairs 101

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Mount the outer brake pad -2- onto the brake plate -1-.

– Mount the brake calliper -1- onto the brake plate -2- together
with the inside brake pad.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Screw the brake calliper onto the brake support plate with the
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
two guide pins and tighten to the respective tightening torque
⇒ Item 11 (page 94) .

– Insert both protective caps -arrows-.

102 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Attach the brake hose -2- to the holder -3- and lock with the
retaining clip -1-.
– Screw on the brake line -4- to the brake hose -2- and tighten
with the respective tightening torque ⇒ Item 17 (page 95) .

– Remove brake pedal depressor - V.A.G 1869/2- .

– Install the retaining spring of the brake calliper -1- so that the
bottom spring support is located behind the brake calliper
-arrow C- and the centre guide pin -arrow B- behind the brake
calliper housing -3-.
– Swivel the top spring support -2- behind the brake calliper
-arrow A-.

1. Front wheel brake: repairs 103

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Connect the connector to the sensor for the brake pad wear
sender -1-.
– Bleed brake system ⇒ page 163 .
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Specified torques of wheel bolts .

WARNING

After fitting the brake pads, operate the brake pedal strongly
with the vehicle stopped so that the brake pads adopt the po‐
sition corresponding to normal operation.

– Check the brake fluid level and refill in case of doubt.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

1.13 Brembo front wheel brake: assembly

permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

overview
General indications ⇒ page 68 .

1 - Brake disc
❑ Allocation, measure‐
ments, wear limits
⇒ page 1
❑ To remove, extract the
brake calliper.
❑ Do not separate the
brake disks from the
wheel hubs by force. If
necessary, use an oxide
solvent; otherwise the
brake disks may be
damaged.
❑ Always replace by axles
2 - Brake caliper
❑ Piston diameter
⇒ page 1
❑ Different versions ⇒
Parts catalogue
❑ To remove the brake
pads, it is not necessary
to remove the brake cal‐
liper
❑ No repair operation is al‐
lowed
3 - Brake pads
❑ Brake pad thickness, wear limit ⇒ page 1
❑ Different versions ⇒ Parts catalogue
❑ Check the thickness of the pads: ⇒ Maintenance ; Booklet 1
❑ Removing and installing ⇒ page 105
❑ Always replace by axles

104 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

4 - Retaining spring
5 - Mounting pin
6 - Security fasteners
7 - Cylindrical bolts, 110 Nm
❑ Renew.
8 - Bracket
❑ Screw it into the brake calliper housing
9 - Brake line, 15 Nm
❑ Screw it into the brake calliper housing
10 - Connector for wear indicator
❑ Not available for Cupra version
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
1.14 Brembo rear brake: brake pads installa‐
respect to the correctness of information in this document. Copyright by SEAT S.A.

tion and removal

1.14.1 Removing

Note

♦ If the brake pads are to be re-used, before removing them from

– Raise the vehicle.

– Remove wheels.

1. Front wheel brake: repairs 105

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Remove security fasteners -1-.

– Using a suitable mandrel, press the support pins out of the
brake calliper to the inside -arrows-. When doing this, press
the pad support spring -3- down a little until the notch of the
support pin protrudes over the edge of the spring.
– Extract the spring from the pad.

Note

♦ Verify the level of brake fluid and, if necessary, remove brake

fluid from the tank, to avoid the liquid spilling when you retract
the pistons.
♦ If brake fluid has been added, before retracting the piston to‐
wards the interior of the cylinder, a part of the liquid must be
sucked from the brake fluid tank, use the brake bleeder - SAT
1175B- . Otherwise brake fluid may spill out causing damage
to the bodywork.

WARNING

Brake fluid is toxic and should never be sucked by mouth using

a flexible tube.

– Press brake pistons slightly back with a suitable plier and with
mounted brakepads.

Note

Ensure that the brake caliper is not damaged or scratched.

– Press pistons back with the thrust tool - T10145-

– Remove brake pads.
Cleanliness:

WARNING

Never clean the brake system with compressed air; harmful

dust particles will be released.

Only alcohol may be used to clean the brake calliper housing.

– Thoroughly clean the brake plate and brake calliper using a
lint free cloth in the brake pad contact areas and remove cor‐
rosion.Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
1.14.2 Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:

Note

Do not damage the protective covers of the pistons when you fit
the brake pads.

– Carefully fit the brake pads.

106 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Fit the pad securing spring and insert the securing pins in the
direction of the -arrow A- on to the brake calliper. When doing
this, press the pad support spring -arrow B- down a little until
the notch of the support pin protrudes over the edge of the
spring.

– Fit security fasteners -arrows-.

– Fit the wheels ⇒ Wheels and tyres; Rep. gr. 44

WARNING

After fitting the brake pads, operate the brake pedal strongly
with the vehicle stopped so that the brake pads adopt the po‐
sition corresponding to normal operation.

– Check the brake fluid level and refill in case of doubt.

1. Front wheel brake: repairs 107

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

2 Rear wheel brake: repairs

Note

WARNING

After fitting the brake pads, operate the brake pedal strongly
with the vehicle stopped so that the brake pads adopt the po‐
sition corresponding to normal operation.

2.1 CI 38 rear brake: assembly overview

General indications ⇒ page 108 .

1 - Speed sensor
❑ Removing and installing
⇒ page 65
❑ Before fitting the speed
sender, clean the inner
surface of the hole and
apply solid lubricant
paste ⇒ Spare parts
catalogue
2 - Hexagon socket head bolt
❑ Specified torque: 8 Nm.
3 - Allen bolt: tighten to 90 Nm
and then tighten another 1/4
turn (90°)
❑ Always replace
4 - Wheel bearing housing
❑ Removing and fitting ⇒
Running gear, axles, Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
steering; Rep. gr. 42 ; permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Rear wheel suspension respect to the correctness of information in this document. Copyright by SEAT S.A.

5 - Splash plate
6 - Hexagonal bolt, 9 Nm / Torx
bolt, 12 Nm
❑ The hexagonal M6x10
bolt has been changed
to a Torx M6x12 bolt
❑ Replace the hexagonal
bolt with another hexag‐
onal bolt and the Torx
bolt with another Torx
bolt.

108 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

7 - Wheel hub with wheel bearing

8 - Brake disc
❑ Allocation, measurements, wear limits ⇒ page 4
❑ Do not separate the brake disks from the wheel hubs by force. If necessary, use an oxide solvent; oth‐
erwise the brake disks may be damaged.
❑ To remove, extract the brake calliper, along with the hollow bolt, the hose and the ring tube.
❑ Always replace by axles
9 - Star bolt -4 Nm
10 - Bolt XZN
❑ Tightening torque ⇒ Running gear, steering shafts; Rep. gr. 42 ; Rear wheel suspension
11 - Brake pads
❑ Brake pad thickness, wear limit ⇒ page 4
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Check
permitted the thickness
unless authorised by SEAT S.A.of theS.Apads:
SEAT does not⇒guarantee
Maintenance ; liability
or accept any Booklet with 1

❑ Removing and installing ⇒ page 109

respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ Always replace by axles

12 - Brake carrier
❑ With guide pin and protection hood
❑ Delivered as assembled part, with sufficient grease on the guide pins
❑ In case of damage to the protection hoods, fit the repair kit ⇒ Parts catalogue , use the grease pad
supplied to grease the guide pins
13 - Housing for brake calliper
❑ Do not unscrew the brake line when replacing brake pads
❑ Piston diameter ⇒ page 4
❑ Removing and installing ⇒ page 112
❑ Repairs ⇒ page 153
❑ Following repairs or a replacement, first adjust the hand brake cable ⇒ page 136
14 - Flexible tube clip
15 - Brake line, 14 Nm
16 - Bolt, 35 Nm
❑ Self-locking
❑ When loosening and tightening, lock the guide pin
❑ Replace after each removal
17 - Hand brake cable
❑ Removing and installing ⇒ page 133
❑ Adjusting handbrake ⇒ page 136
18 - Elastic hook
19 - Brake hose, 38 Nm

2.2 CI 38 brake blocks: removal and instal‐

lation
Special tools and workshop equipment required

2. Rear wheel brake: repairs 109

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

♦ Torque wrench kit - SAT 8010-

♦ Opening/closing wrench - T10165-

2.2.1 Removing

Note

If the brake pads are to be re-used, before removing them from

the brake carrier, mark their positions for posterior fitting. Put them
back in the same positions, otherwise, the braking effect will not
be even.

– Remove wheels.
– Remove securing bolts from brake calliper, when doing this
counter-hold on guide pins.
– Remove brake caliper and secure with wire so that weight of
brake caliper does not strain or damage brake hose.
– Remove brake pads.
Cleanliness:

WARNING

Never clean the brake system with compressed air; harmful

dust particles will be released.

– Thoroughly clean the brake plate in the areas of contact with

the brake pads and remove corrosion.
– Clean the brake calliper, especially the adhesive surface for
the brake pads, they must be free of adhesive residues and
grease.
Use only methylated spirits for cleaning the brake caliper housing.

110 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

2.2.2 Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:

Note

♦ Before mounting of new brake pad open/close piston with the

wrench - T10165- push in cylinder.
♦ If brake fluid has been added, before retracting the piston to‐
wards the interior of the cylinder, a part of the liquid must be
sucked from the brake fluid tank, use the brake bleeder - SAT
1175B- . Otherwise brake fluid may spill out causing damage
to the bodywork.

WARNING

Brake fluid is toxic and should never be sucked by mouth using

a flexible tube.

– Use the plate to screw in the - T10165/1- piston.

– Press the pistons in by clockwise rotation with opening/closing
wrench - T10165- , ensure that the protective cap is not dam‐
aged.
♦ If piston will not move easily, a 13 mm open-end spanner can
be applied at the flats provided -arrow A-.
– Pull protective foil off backing plates for brake pads.

When applying the brake calliper, care should be taken that the
brake pads do not get stuck together with the brake calliper before
the correct fitting location has been reached.
– Secure brake caliper with new self-locking bolts
⇒ Item 16 (page 109) .
♦ The repair kit contains four auto-locking hexagonal bolts that
must always be fitted.
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Specified torques of wheel bolts .

Note

♦ After every brake pad change, depress brake pedal firmly sev‐
eral times with vehicle stationary, so that brake pads are
properly seated in their normal operating position.
♦ Check brake fluid level after changing brake pads.

2. Rear wheel brake: repairs 111

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

2.3 CI 38 brake caliper: removal and instal‐

lation
Special tools and workshop equipment required
♦ Torque wrench kit - SAT 8010-

♦ Brake pedal depressor - V.A.G 1869/2-

2.3.1 Removing
The following process is only required to replace the brake calliper
or for the repair work described below.
– Remove wheels.
– Hang the handbrake cable out of the lever on the brake cal‐
liper.
– Remove the spring clip and pull the handbrake cable out of the
lever on the brake calliper.
– Attach the bleeding hose of the bleeding bottle - SAT 1175B/
1- on the bleeding bolt of the brake caliper and open the bleed‐
ing bolt.
– Apply brake pedal depressor - V.A.G 1869/2- .
– Close the bleeding valve and remove - SAT 1175B/1- remove
the bleeding bottle.
– Unscrew brake line.

112 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Unscrew both securing bolts from the brake calliper, counter‐

hold the guide bolts for this purpose.
– Remove the brake calliper from the brake back plate.

2.3.2 Installing
• The piston is removed.
• The brake pads are seated on the brake back plate.
– Secure brake caliper to brake carrier with new self-locking
bolts. ⇒ Item 16 (page 109) .
– Screw brake line onto brake caliper ⇒ Item 19 (page 109) .
– Bleeding air from the brake system ⇒ page 163 .
– Hook the hand brake cable and fasten it to the support with
the elastic clip.
– Adjusting handbrake ⇒ page 136
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Specified torques of wheel bolts .

Note

♦ Step on the brake pedal a few times with the vehicle stationary,
so that the pads reach their working position.
♦ Check brake fluid level.

2.4 CII 38 HR rear brake: assembly over‐

General indications ⇒ page 108 .

2. Rear wheel brake: repairs 113

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

1 - Speed sensor
❑ Removing and installing
⇒ page 65
❑ Before fitting the speed
sender, clean the inner
surface of the hole and
apply solid lubricant
paste ⇒ Spare parts
catalogue
2 - Hexagon socket head bolt
❑ Specified torque: 8 Nm.
3 - Bolt
❑ Tightening torque: 90
Nm + 90°
❑ Replace after each re‐
moval
4 - Wheel bearing housing
5 - Splash plate
6 - Torx bolt
❑ Specified torque: 12
Nm.
7 - Wheel hub with wheel bear‐
ing
8 - Brake disc
❑ Allocation, measure‐
ments, wear limits
⇒ page 4
❑ Do not separate the
brake disks from the
wheel hubs by force. If
necessary, use an oxide
solvent; otherwise the
brake disks may be
damaged.
❑ To remove, extract the brake calliper, along with the hollow bolt, the hose and the ring tube.
❑ Always replace by axles
9 - Cross-head screw
❑ Specified torque: 4 Nm.
10 - Bolt
❑ Only with front wheel drive
11 - Brake pads
❑ Brake pad thickness, wear limit ⇒ page 4
❑ Check the thickness of the pads: ⇒ Maintenance ; Booklet 1
❑ Removing and installing ⇒ page 115
❑ Always replace by axles
12 - Brake carrier
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ With guide pin and protection hoodauthorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
permitted unless

❑ Delivered as assembled part, with sufficient grease on the guide pins

respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ In case of damage to the protection hoods, fit the repair kit ⇒ Parts catalogue , use the grease pad
supplied to grease the guide pins
13 - Brake pad retention springs
❑ Always renew when changing pads.

114 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

14 - Housing for brake calliper

❑ Do not unscrew the brake line when replacing brake pads
❑ Piston diameter ⇒ page 4
❑ Removing and installing ⇒ page 117
❑ Repairs ⇒ page 153
❑ Following repairs or a replacement, first adjust the hand brake cable ⇒ page 136
15 - Flexible tube clip
16 - Brake line
❑ Specified torque: 14 Nm.
17 - Bolt
❑ Specified torque: 35 Nm.
❑ Self-locking
❑ When loosening and tightening, lock the guide pin
❑ Replace after each removal
18 - Hand brake cable
❑ Removing and installing ⇒ page 133
❑ Adjusting handbrake ⇒ page 136
19 - Elastic hook
20 - Brake hose
❑ Specified torque: 38 Nm.

2.5 CII 38 HR brake blocks: removal and in‐

stallation
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Special tools and workshop equipment
permitted unless required
authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
♦ Torque wrench kit - SAT 8010-

♦ Opening/closing wrench - T10165-

2. Rear wheel brake: repairs 115

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

2.5.1 Removing

Note

If the brake pads are to be re-used, before removing them from

the brake carrier, mark their positions for posterior fitting. Put them
back in the same positions, otherwise, the braking effect will not
be even.

– Remove wheels.
– Remove securing bolts from brake calliper, when doing this
counter-hold on guide pins.
– Remove brake calliper and secure with wire so that weight of
brake calliper does not strain or damage brake hose.

– Remove brake pads and pad retainers -arrows-.

Cleanliness:

WARNING

Never clean the brake system with compressed air; harmful

dust particles will be released.

– Thoroughly clean the application surface for the pad retention

plate (brake pads) on the brake calliper, remove any corrosion.
– Clean the brake calliper.
Use only methylated
Protectedspirits for Copying
by copyright. cleaning the orbrake
for private calliper
commercial hous‐
purposes, in part or in whole, is not
ing. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

2.5.2 Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:

Note

♦ Before mounting of new brake pad open/close piston with the

wrench - T10165- push in cylinder.
♦ If brake fluid has been added, before retracting the piston to‐
wards the interior of the cylinder, a part of the liquid must be
sucked from the brake fluid tank, use the brake bleeder - SAT
1175B - . Otherwise brake fluid may spill out causing damage
to the bodywork.

116 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

WARNING

Brake fluid is toxic and should never be sucked by mouth using

a flexible tube.

– Screw piston on knurling wheel through open/close clock wise

rotation on knurling wheel of wrench - T10165- , ensure that
the protective cap is not damaged.
– Use the plate to screw in the - T10165/1- piston.
♦ If piston will not move easily, a 13 mm open-end spanner can
be applied at the flats provided -arrow A-.

– Insert pad retainers -arrows- and brake pads into brake carrier.

– Ensure that brake pads are seated correctly in pad retainers

-arrows-.
– Secure brake caliper with new self-locking bolts
⇒ Item 17 (page 115) .
♦ The repair kit contains four auto-locking hexagonal bolts that
must always be fitted.
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Specified torques of wheel bolts .

Note

2.6 CII 38 HR brake calipers: removal and

installation
Special tools and workshop equipment required

2. Rear wheel brake: repairs 117

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

♦ Torque wrench kit - SAT 8010-

♦ Brake pedal depressor - V.A.G 1869/2-

2.6.1 Removing
The following process is only required to replace the brake calliper
or for the repair work described below.
– Remove wheels.
– Hang the handbrake cable out of the lever on the brake cal‐
liper.
– Remove the spring clip and pull the handbrake cable out of the
lever on the brake calliper.
– Attach the bleeding hose of the bleeding bottle - SAT 1175B/
1- on the bleeding bolt of the brake calliper and open the
bleeder screw.
– Apply brake pedal depressor - V.A.G 1869/2- .
– Close the bleeding valve and remove - SAT 1175B/1- remove
the bleeding bottle.
– Unscrew brake line.
– Unscrew both securing bolts from the brake calliper, counter‐
hold the guide bolts for this purpose.
– Remove the brake calliper from the brake back plate.

118 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

2.6.2 Installing
• The piston is removed.
• The brake pads are seated in the retaining springs on the
brake carrier.
– Secure brake caliper to brake carrier with new self-locking
bolts. ⇒ Item 17 (page 115) .
– Screw brake line onto brake caliper ⇒ Item 20 (page 115) .
– Bleeding air from the brake system ⇒ page 163 .
– Hook the hand brake cable and fasten it to the support with
the elastic clip.
– Adjust handbrake ⇒ page 136 .
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Specified torques of wheel bolts .

Note

♦ Step on the brake pedal a few times with the vehicle stationary,
so that the pads reach their working position.
♦ Check brake fluid level.

2.7 CII 41 HR TRW rear axle brake: assem‐

bly overview
General indications ⇒ page 108 .
I - Assembly overview, front-wheel drive
II - Differences for all-wheel drive vehicles

2. Rear wheel brake: repairs 119

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

1 - ABS rev. sensor

❑ Removal and assembly,
front-wheel drive
⇒ page 65
❑ Removal and assembly,
four-wheel drive
⇒ page 67
❑ Before inserting sensor,
clean interior of the hole
and apply heat resistant
paste to the bolts ⇒
Spare parts catalogue
2 - Allen screw, 8 Nm
3 - Interior notched-head bolt,
90 Nm and retighten 90°
❑ Replace after each re‐
moval
❑ Install and remove with -
T10035- ⇒ page 121
plug insert .
4 - Wheel bearing housing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
5 - Splash plate respect to the correctness of information in this document. Copyright by SEAT S.A.

6 - Hexagonal bolt, 9 Nm / Torx

bolt, 12 Nm
❑ The hexagonal M6x10
bolt has been changed
to a Torx M6x12 bolt
❑ Replace the hexagonal
bolt with another hexag‐
onal bolt and the Torx
bolt with another Torx
bolt.
7 - Wheel hub with wheel bear‐
ing
8 - Brake disc
❑ Allocation, measurements, wear limits ⇒ page 4
❑ Do not separate the brake disks from the wheel hubs by force. If necessary, use an oxide solvent; oth‐
erwise the brake disks may be damaged.
❑ To remove, extract the brake calliper, along with the hollow bolt, the hose and the ring tube.
❑ Always replace by axles
9 - Star bolt -4 Nm
10 - Bolt
❑ Only with front wheel drive
11 - Brake pads
❑ Brake pad thickness, wear limit ⇒ page 4
❑ Check the thickness of the pads: ⇒ Maintenance ; Booklet 1
❑ Removing and installing ⇒ page 122
❑ Always replace by axles
12 - Brake holder with different guide bolts and protective hoods
❑ Delivered as assembled part, with sufficient grease on the guide pins
❑ Fit the repair unit if protective hoods or guide bolts are damaged. Use the bag of grease attached to
grease the guide bolts
❑ Installation instructions: ⇒ page 121

120 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

13 - Brake pad retention springs

❑ Always renew when changing pads.
14 - Brake caliper
❑ Do not disconnect brake hose when changing pads.
❑ Piston diameter ⇒ page 4
❑ Removing and installing ⇒ page 124
❑ Repairs ⇒ page 153
❑ Following repair or replacement work, the handbrake cable should first be adjusted.
❑ Adjusting handbrake ⇒ page 136
15 - Flexible tube clip
16 - Brake line, 14 Nm
17 - Hexagonal bolt, self-locking - 35 Nm
❑ Renew.
18 - Hand brake cable
❑ Adjusting handbrake ⇒ page 136
19 - Elastic hook
20 - Brake hose

Brake holder installation instructions:

1- Shortest guide bolt with steps -arrows-, on input side.
2- Longest guide bolt on output side.
3- Vibration damper, on output side.

Tool insert - T10035-

2. Rear wheel brake: repairs 121

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

2.8 CII 41 HR TRW brake pads: removal

and installation
Special tools and workshop equipment required
♦ Torque wrench kit - SAT 8010-

♦ Opening/closing wrench - T10165-

2.8.1 Removing

Note

If the brake pads are to be re-used, before removing them from

the brake carrier, mark their positions for posterior fitting. Put them
back in the same positions, otherwise, the braking effect will not
be even.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Remove wheels. respect to the correctness of information in this document. Copyright by SEAT S.A.

– Remove securing bolts from brake calliper, when doing this

counter-hold on guide pins.
– Remove brake calliper and secure with wire so that weight of
brake calliper does not strain or damage brake hose.

122 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Remove brake pads and pad retainers -arrows-.

Cleanliness:

WARNING

Never clean the brake system with compressed air; harmful

dust particles will be released.

– Thoroughly clean the application surface for the pad retention

plate (brake pads) on the brake calliper, remove any corrosion.
– Clean the brake calliper.
Use only methylated spirits for cleaning the brake calliper hous‐
ing.

2.8.2 Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:

Note

♦ Before mounting of new brake pad open/close piston with the

WARNING

Brake fluid is toxic and should never be sucked by mouth using

a flexible tube.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Screw piston
permitted unless on knurling
authorised wheel
by SEAT through
S.A. SEAT S.A doesopen/close
not guarantee orclock wise
accept any liability with
rotationrespect
on knurling wheel
to the correctness of wrench
of information - document.
in this T10165- , ensure
Copyright that
by SEAT S.A.
the protective cap is not damaged.
– Use the plate to screw in the - T10165/1- piston.
♦ If piston will not move easily, a 13 mm open-end spanner can
be applied at the flats provided -arrow A-.

2. Rear wheel brake: repairs 123

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Insert pad retainers -arrows- and brake pads into brake carrier.

– Ensure that brake pads are seated correctly in pad retainers

-arrows-.
– Secure brake caliper with new self-locking bolts
⇒ Item 17 (page 121) .
♦ The repair kit contains four auto-locking hexagonal bolts that
must always be fitted.
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Specified torques of wheel bolts .

Note

2.9 CII 41 HR TRW brake caliper: removal

and installation
Special tools and workshop equipment required
♦ Torque wrench kit - SAT 8010-

124 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

♦ Brake pedal depressor - V.A.G 1869/2-

2.9.1 Removing
The following process is only required to replace the brake calliper
or for the repair work described below.
– Remove wheels.
– Hang the handbrake cable out of the lever on the brake cal‐
liper.
– Remove the spring clip and pull the handbrake cable out of the
lever on the brake calliper.
– Attach the bleeding hose of the bleeding bottle - SAT 1175B/
1- on the bleeding bolt of the brake calliper and open the
bleeder screw.
– Fit the block for the brake pedal - V.A.G 1869/2- .
– Close the bleeding valve and remove - SAT 1175B/1- remove
the bleeding bottle.
– Unscrew brake line.
– Unscrew both securing bolts from the brake calliper, counter‐
hold the guide bolts for this purpose.
– Remove the brake calliper from the brake back plate.

2.9.2 Installing
• The piston is removed.
• The brake pads are seated in the retaining springs on the
brake carrier.
– Secure brake caliper to brake carrier with new self-locking
bolts. ⇒ Item 17 (page 121) .
– Screw brake line onto brake caliper ⇒ Item 16 (page 121) .
– Bleeding air from the brake system ⇒ page 163 .
– Hook the hand brake cable and fasten it to the support with
the elastic clip.
– Adjust handbrake ⇒ page 136 .

2. Rear wheel brake: repairs 125

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Specified torques of wheel bolts .

Note

♦ Step on the brake pedal a few times with the vehicle stationary,
so that the pads reach their working position.
♦ Check brake fluid level.

2.10 ZOH 38 BIR III Bosch rear axle brake:

assembly overview
General indications ⇒ page 108 .

1 - ABS rev. sensor

❑ Removing and installing
⇒ page 65
❑ Before fitting the speed
sender, clean the inner
surface of the hole and
apply solid lubricant
paste ⇒ Spare parts
catalogue
2 - Bolt
❑ Specified torque: 8 Nm.
3 - Bolt
❑ Tightening torque: 90
Nm + 90°
❑ Replace after each re‐
moval
4 - Wheel bearing housing
5 - Splash plate
6 - Bolt
❑ Specified torque: 12
Nm. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
7 - Wheel hub with wheel bear‐ respect to the correctness of information in this document. Copyright by SEAT S.A.

ing
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
8 - Bolt
❑ Only with front wheel
drive
9 - Protective cap
❑ Allocation according to
the version ⇒ Electronic
parts catalogue “ETKA”
10 - Brake disc
❑ Allocation, measurements, wear limits ⇒ page 4
❑ Do not separate the brake disks from the wheel hubs by force. If necessary, use an oxide solvent; oth‐
erwise the brake disks may be damaged.
❑ To remove, extract the brake calliper, along with the hollow bolt, the hose and the ring tube.
❑ Always replace by axles

126 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

11 - Bolt
❑ Specified torque: 4 Nm.
12 - Brake pads
❑ Brake pad thickness, wear limit ⇒ page 4
❑ Check the thickness of the pads: ⇒ Maintenance ; Booklet 1
❑ Removing and installing ⇒ page 127
❑ Always replace by axles
13 - Brake carrier
❑ With guide pin and protection hood
❑ Delivered as assembled part, with sufficient grease on the guide pins
❑ In case of damage to the protection hoods, fit the repair kit ⇒ Parts catalogue , use the grease pad
supplied to grease the guide pins
14 - Brake pad retention springs
❑ Always renew when changing pads.
15 - Retaining plate of the brake pads
❑ Always renew when changing pads.
16 - Brake caliper
❑ Do not unscrew the brake line when replacing brake pads
❑ Piston diameter ⇒ page 4
❑ Removing and installing ⇒ page 130
❑ Repairs ⇒ page 153
❑ Following repairs or a replacement, first adjust the hand brake cable ⇒ page 136
17 - Bolt
❑ Specified torque: 35 Nm.
❑ Self-locking
❑ When loosening and tightening, lock the guide pin
❑ Replace after each removal
18 - Hand brake cable
❑ Removing and installing ⇒ page 133
❑ Adjusting handbrake ⇒ page 136
19 - Brake hose
❑ Specified torque: 35 Nm.

2.11 ZOH 38 BIR III Bosch brake pads: re‐

moval and installation
Special tools and workshop equipment required
♦ Torque wrench kit - SAT 8010-

2. Rear wheel brake: repairs 127

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

♦ Opening/closing wrench - T10165-

2.11.1 Removing

Note

If the brake pads are to be re-used, before removing them from

the brake carrier, mark their positions for posterior fitting. Put them
back in the same positions, otherwise, the braking effect will not
be even.

– Remove wheels.
– Unscrew the fixing screws -arrows- of the brake calliper. Lock
the guide pins for this purpose. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Remove brake caliper and secure with wire sotothat
respect weight ofofinformation in this document. Copyright by SEAT S.A.
the correctness
brake caliper does not strain or damage brake hose.

– Remove brake pads and pad retainers -arrows-.

Cleanliness:

WARNING

Never clean the brake system with compressed air; harmful

dust particles will be released.

– Thoroughly clean the application surface for the pad retention

plate (brake pads) on the brake calliper, remove any corrosion.
– Clean the brake calliper.
Use only methylated spirits for cleaning the brake caliper housing.

2.11.2 Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:

128 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

Note

♦ Before mounting of new brake pad open/close piston with the

WARNING

Brake fluid is toxic and should never be sucked by mouth using

a flexible tube. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Use the plate to screw in the - T10165/1- piston.

– Screw in pistons through clockwise turning on knurling wheel
of open/close wrench - T10165- , do not damage protective
cap.
♦ If piston will not move easily, a 13 mm open-end spanner can
be applied at the flats provided -arrow A-.

– Mount the retaining plates of the brake pads -1- and -2- onto
the brake plate.

Note

The retaining plates of the brake pads -1- and -2- are different.
They can only be mounted diagonally to each other.

– Mount the retaining plates of the brake pads -1- and -2- in such
a way that the guide pins -arrows- show to the outside on both
sides of the brake plates.
– Insert brake pads into brake holder.

2. Rear wheel brake: repairs 129

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Ensure that brake pads are seated correctly in pad retainers

-arrows-.
– Secure brake caliper with new self-locking bolts
⇒ Item 17 (page 127) .
♦ The repair kit contains four auto-locking hexagonal bolts that
must always be fitted.
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Specified torques of wheel bolts .

Note

2.12 ZOH 38 BIR III Bosch brake calipers: re‐

moval and installation
Special tools and workshop equipment required
♦ Torque wrench kit - SAT 8010-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

♦ Brake pedal depressor - V.A.G 1869/2-

2.12.1 Removing
The following process is only required to replace the brake calliper
or for the repair work described below.
– Remove wheels.

130 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Hang out the handbrake cable -1- from the lever on the brake
calliper -2-.
– Press the tabs -3- together and remove the handbrake cable
from the holder -4- on the brake calliper.

– Attach the breather hose -1- of the bleeding bottle - SAT

1175B/1- onto the breather valve of the brake calliper and
open the breather valve.

– Fit the block for the brake pedal - V.A.G 1869/2-

– Close the bleeding valve and remove - SAT 1175B/1- remove
the bleeding bottle.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Loosen the connection of the brake hose -1- using the banjo
bolt -2- on the brake calliper.

2. Rear wheel brake: repairs 131

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Unscrew the fixing screws -arrows- of the brake calliper -1-.

The guide pins must be locked for this purpose.
– Remove the brake calliper from the brake back plate.

2.12.2 Installing
• The piston is removed.
• The brake pads are seated in the retaining springs on the
brake carrier.
– Secure brake caliper to brake carrier with new self-locking
bolts. ⇒ Item 17 (page 127) .
– Screw brake line onto brake caliper ⇒ Item 19 (page 127) .
– Bleeding air from the brake system ⇒ page 163 .
– Hook the hand brake cable and fasten it to the support with
the elastic clip.
– Adjust handbrake ⇒ page 136 .
– Fit wheels.
Specified torque of wheel bolts ⇒ Running gear, axles, steering;
Rep. gr. 44 ; Specified torques of wheel bolts .

Note

♦ Step on the brake pedal a few times with the vehicle stationary,
so that the pads reach their working position.
♦ Check brake fluid level.

132 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

3 Handbrake

3.1 Parking brake: assembly overview

1 - Hand brake cable

❑ Removing and installing
⇒ page 133
❑ Adjusting handbrake
⇒ page 136
2 - Expansion tab
3 - Adjustment nut, 8 Nm
❑ Self-locking
❑ To adjust the handbrake
❑ Adjusting handbrake
⇒ page 136
4 - Handbrake warning switch
- F9-
❑ Renewing ⇒ page 137 .
5 - Locking knob
❑ Removing and installing
the hand brake lever
covering ⇒ Bodywork,
interior fitting work; Rep.
gr. 68
6 - Handbrake lever
❑ This is supplied as an
assembled part with a
traction bar, ratchet fit‐
ting, operation rod,
pressure button, pres‐
sure spring and lock
ring.
❑ Remove the centre con‐
sole before dismantling Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
⇒ Body - interior body respect to the correctness of information in this document. Copyright by SEAT S.A.
assembly work ; Rep.
gr. 68
❑ Removing and installing
the hand brake lever covering ⇒ Bodywork, interior fitting work; Rep. gr. 68
7 - Hexagon nut, 15 Nm
8 - Trim upholstery
❑ Removing and installing the hand brake lever covering ⇒ Bodywork, interior fitting work; Rep. gr. 68

3.2 Hand brake cable: removing and instal‐

ling

3.2.1 Removing
– Put the hand brake lever in the rest position, downwards.

3. Handbrake 133
Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Partially unscrew the bolts attaching the centre console, do not

completely remove the console ⇒ Bodywork, interior fitting
work; Rep. gr. 68
– Lift the console in the direction of the arrow.

– Loosen the adjustment nut -arrow- to release the hand brake

cables from the compensation brace.

– Lever and extract the attachment securing the hand brake ca‐
ble to the bracket-1- .
– Push the brake lever -2- in the direction of the -arrow- and
release the hand brake cable -3- from the lever -2-.

– Remove the Torx bolt -1-.

134 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Release the hand brake cable from the bracket -1- and remove
it from the guide rail -2-.

3.2.2 Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:
– Insert the hand brake cable into the guide rail -2- and secure
it to the bracket -1-.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Fit the hand brake cable -2- to the body of the rear axle.

– Operate the brake lever -2- in the direction of the -arrow- and
insert the hand brake cable -3- onto the lever -2-.
– Insert the attachment -1- to secure the hand brake cable to its
bracket.

3. Handbrake 135
Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Fit the hand brake cable to the compensation bracket and

tense the hand brake cable using the adjustment bolt
-arrow-.
– Installing the central console ⇒ Bodywork, interior fitting work;
Rep. gr. 68
– Adjust handbrake ⇒ page 136 .

3.3 Adjust handbrake.

Note

The new adjustment is only necessary if the hand brake cable,

the brake callipers or the brake disks have been replaced.

– Remove the rear cover of the central console ⇒ Interior body

installation work; Rep. gr. 68 .
– Place the hand brake lever in rest position.
– Tighten the readjustment nut -arrow (magnifying glass)-until
the Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

136 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– ... lever -1- is separated from the limit -2- on the brake calliper.
– The measurement -a- to the limit -2- in the left and right hand
side brake callipers should not be less than 1 mm or larger
than 4 mm.
The distance on one side must be more than 0 mm and not more
than 3 mm.
– Operate the hand brake 3 times strongly, releasing it once
more.
– With the hand brake released, check if the rear wheels may
rotate fully. And if the clearance -a- to the brake saddle stays
the same.
If necessary, correct the adjustment using the adjustment nut.

Note

When automatically readjusting the rear wheel brake, following

the new adjustment there is no need to readjust the hand brake.

3.4 Handbrake control switch - F9- : replace

Removing
With Leon model:
– Removing central console ⇒ Bodywork, interior fitting work;
Rep. gr. 68
With models Altea, Altea XL, Altea XL Freetrack:
– Removing central console ⇒ Bodywork, interior fitting work;
Rep. gr. 68
Continuation for all models:
– Move the drivers seat forward.
– Unclip connectors -A- of the handbrake warning switch - F9-
-B-.
– Clip out the securing tabs -arrows- of the handbrake warning
switch - F9- -B- and remove.
Installing
Install in reverse order.

3. Handbrake 137
Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

4 Brake pedal

4.1 Brake pedal, vehicles with the steering

wheel on the left - assembly overview

WARNING

The brake pedal stroke must not be obstructed by fitting extra

coverings to the footwell.

1 - Support buck
2 - Hexagon nut, 25 Nm
3 - Brake light switch - F- and
brake pedal switch - F47-
❑ In vehicles manufac‐
tured from week 45/05,
the brake pedal position
sender - G100- is loca‐
ted on the brake pump
⇒ page 169
❑ Before fitting the brake
light switch - F- and
brake pedal switch -
F47- insert the brake
pedal with the push rod
into the servo brake
❑ Removing, installing
and adjusting
⇒ page 28
❑ Before fitting, grease
the rod with grease ac‐
cording to the ⇒ Parts
catalogue
4 - Hexagon bolt
5 - Brake pedal
❑ Removing and installing
⇒ page 140
❑ separate from servo
brake ⇒ page 140 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Before fitting, grease
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
the contact
respect surfaces
to the correctness of information in this document. Copyright by SEAT S.A.
with grease ⇒ Parts
catalogue
6 - Trim upholstery
7 - Ball socket
8 - Mounting
❑ For the spherical head of the servo-brake control rod
9 - Hexagon nut, 25 Nm
10 - Sleeve bearing
❑ Before fitting, grease the bearing bush surfaces with grease ⇒ Parts catalogue
11 - Pivot pin

138 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

4.2 Brake pedal, vehicles with the steering

wheel on the left (automatic gearbox) -
assembly overview

WARNING

The brake pedal stroke must not be obstructed by fitting extra

coverings to the footwell.

1 - Support buck
2 - Hexagon nut, 25 Nm
3 - Brake light switch - F- and
brake pedal switch - F47-
❑ In vehicles manufac‐
tured from week 45/05,
the brake pedal position
sender - G100- is loca‐
ted on the brake pump
⇒ page 169
❑ Before fitting the brake
light switch - F- and
brake pedal switch -
F47- insert the brake
pedal with the push rod
into the servo brake
❑ Removing, installing
and adjusting
⇒ page 28
❑ Before fitting, grease
the head of the push rod
with grease ⇒ Parts
catalogue
4 - Hexagon bolt
5 - Brake pedal
❑ Removing and installing
⇒ page 140
❑ separate from servoProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not
brake ⇒ page 140 . respect to the correctness of information in this document. Copyright by SEAT S.A.
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

❑ Before fitting, grease

the bearing bush surfa‐
ces with grease ⇒ Parts
catalogue
6 - Trim upholstery
7 - Ball socket
8 - Mounting
❑ For the spherical head of the servo-brake control rod
9 - Hexagon nut, 25 Nm
10 - Sleeve bearing
❑ Before fitting, grease the bearing bush surfaces with grease ⇒ Parts catalogue
11 - Pivot pin

4. Brake pedal 139

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

4.3 Removing and installing brake pedal

4.3.1 Removing
– Remove the lower trim of the driver's side foot well ⇒ Body‐
work, interior work; Rep. gr. 68 ; Stowage compartment,
coverings and trims .
– Release and unplug the connector from the brake light switch
- F- and the brake pedal switch - F47 - , remove the switch
from its bracket, rotating 45° to the left hand side.
– Separate the brake pedal from the servo brake ⇒ page 140 .
– Unscrew the hexagonal bolt securing the brake pedal to the
bracket.

4.3.2 Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:

Note

Before fitting, grease the bearing bush surfaces with grease ⇒

Parts catalogue

– Hold the ball joint of the control rod in front of its housing and
press the brake pedal in the direction of the servobrake, so
that the ball joint inserts audibly.
– Fit the brake light switch - F- and the brake pedal switch - F47-
and plug in the connector ⇒ page 28 .
– Fit the lower trim of the driver's side foot well ⇒ Bodywork,
interior work; Rep. gr. 68 ; Stowage compartment, coverings
and trims .

4.4 Separating brake permitted

pedal from brake ser‐
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

vo
respect to the correctness of information in this document. Copyright by SEAT S.A.

4.4.1 Removing
Special tools and workshop equipment required
♦ Thrust piece - T20179 -

140 Rep. gr.46 - Brakes - mechanism

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Remove the lower trim of the driver's side foot well ⇒ Body‐
work, interior work; Rep. gr. 68 ; Stowage compartment,
coverings and trims .
– Release and unplug the connector from the brake light switch
- F- and the brake pedal switch - F47 - , remove the switch
from its bracket, rotating 45° to the left hand side.
– Separate the brake pedal from the brake servo using the cal‐
liper tool - T20179 - .
– Fit and press the release tool - T20179 - ; move the brake
pedal towards the driver's seat (this separates the brake pedal
from the control rod swivel head).

4.4.2 Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:
– Hold the spherical head of the control rod in front of the hous‐
ing bracket and press on the brake pedal towards the servo /
brake until the spherical head inserts audibly.
– Fit the Brake light switch - F- and brake pedal switch - F47-
⇒ page 28 .
– Fit the lower trim of the driver's side foot well ⇒ Bodywork,
interior work; Rep. gr. 68 ; Stowage compartment, coverings
and trims .

4. Brake pedal 141

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

47 – Brakes - hydraulics
1 High and low pressure testing
⇒ “1.1 High pressure test”, page 142
⇒ “1.2 Low-pressure test”, page 143
Special tools and workshop equipment required
♦ Tester for brake pressure regulator - VAG 1310A -

♦ Brake pedal depressor - V.A.G 1869/2-

Note

Check the operation and the seal of the brake system (brake
master cylinder, brake hoses, brake tubes and callipers).

1.1 High pressure test

– Unscrew the bleeding bolt from one of the front brake callipers.
Connect the brake tester - VAG 1310A- and purge of air.
– Fit the brake pedal lock - V.A.G 1869/2- between the brake
pedal and the driver's seat. Press the brake pedal until the
pressure gauge indicates 50 bar of pressure. The pressure
must not drop by more than 4 bar within the test period of
45 seconds.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
If the permitted
drop inunless
pressure
authorisedisbygreater, thenS.Athe
SEAT S.A. SEAT doesbrake master
not guarantee cylinder
or accept any liability with
must be replaced.
respect to the correctness of information in this document. Copyright by SEAT S.A.

142 Rep. gr.47 - Brakes - hydraulics

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

1.2 Low-pressure test

– Retract the brake pedal block - V.A.G 1869/2- until the pres‐
sure gauge indicates 6 bar of pressure.
– The pressure should not drop by more than 1 bar within the
test period of 3 minutes.
If the drop in pressure is greater, then the brake master cylinder
must be replaced.

1. High and low pressure testing 143

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

2 Front brake calliper: repair

⇒ “2.1 FS 3 brake calliper: Assembly overview”, page 144
⇒ “2.2 Brake caliper FN 3: assembly overview”, page 145
⇒ “2.3 FNR G brake calliper (Model Leon 2006 Cupra):”,
page 146
⇒ “2.5 FNR G brake calliper (Model Leon 2009 Cupra and Cupra
R): Assembly overview”, page 149

Note

♦ When carrying out repairs, install all parts supplied in repair

kit.
♦ New brake calipers are filled with brake fluid and are pre-bled.
♦ Apply a fine layer of assembly paste to the brake cylinder, the
piston and the seal ring ⇒ Parts catalogue .

2.1 FS 3 brake calliper: Assembly overview

⇒ “2.4 Removing and installing pistons for front brake calliper”,
page 147

1 - Protective cap
2 - Air drain plug, 10 Nm
❑ Before tightening, apply Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
a fine layer of assembly
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
paste to the screw
thread ⇒ Parts cata‐
logue
3 - Cover caps
❑ Insert into sleeve bear‐
ing.
4 - Guide pin, 28 Nm
5 - Sleeve bearing
❑ Insert into brake caliper.
6 - Brake caliper
7 - Protective cap
❑ Pull on so that outer
sealing lip goes over
piston.
❑ Removing and installing
⇒ page 148
8 - Piston
❑ Removing and installing
⇒ page 147
❑ Before tightening, apply
a fine layer of assembly
paste to the screw
thread ⇒ Parts cata‐
logue
9 - Sealing ring
❑ Take care not to dam‐
age when inserting pis‐

144 Rep. gr.47 - Brakes - hydraulics

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

ton.
❑ Removing and installing ⇒ page 148

2.2 Brake caliper FN 3: assembly overview

⇒ “2.4 Removing and installing pistons for front brake calliper”,
page 147

1 - Protective cap
2 - Air drain plug, 10 Nm
❑ Before tightening, apply
a fine layer of assembly
paste to the screw
thread ⇒ Parts cata‐
logue
3 - Cover caps
❑ Insert into sleeve bear‐
ing.
4 - Guide pin, 30 Nm
5 - Sleeve bearing
❑ Fit into the brake calliper
housing
6 - Housing for brake calliper
7 - Brake carrier
❑ Tighten with the brake
calliper housing
8 - Retaining spring
❑by copyright.
Protected Hook into thefortwo
Copying holes
private or commercial purposes, in part or in whole, is not
permitted unlessin the brake
authorised by SEATcalliper
S.A. SEAT S.A does not guarantee or accept any liability with
housing
respect to the correctness of information in this document. Copyright by SEAT S.A.

9 - Sealing ring
❑ Take care not to dam‐
age when inserting pis‐
ton.
❑ Removing and installing
⇒ page 147
10 - Piston
❑ Removing and installing
⇒ page 147
❑ Apply a thin coating of assembly paste to the piston ⇒ Parts catalogue
11 - Protective cap
❑ Pull on so that outer sealing lip goes over piston.
❑ Take care not to damage when inserting piston.
❑ Removing and installing ⇒ page 148

2. Front brake calliper: repair 145

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

2.3 FNR G brake calliper (Model Leon 2006

Cupra):
⇒ “2.4 Removing and installing pistons for front brake calliper”,
page 147

Note

♦ When repairing, fit the whole repair unit.

♦ To clean the brake pads only methylated spirits may be used.
♦ Apply a thin coating of assembly paste (assignment ⇒ Electronic parts catalogue (ETKA) ) to the brake
cylinder, pistons and seals.

1 - Brake carrier
❑ Tighten with the brake
calliper housing
2 - Guide pin, 30 Nm
3 - Cover caps
❑ Insert into sleeve bear‐
ing.
4 - Protective cap
❑ Fit it over the bleed
valve
5 - Air drain plug, 15 Nm
❑ Before tightening, apply
a fine layer of assembly
paste to the screw Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
thread ⇒ Parts cata‐ permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
logue respect to the correctness of information in this document. Copyright by SEAT S.A.

6 - Sleeve bearing
❑ Fit into the brake calliper
housing
7 - Housing for brake calliper
8 - Retaining spring
❑ Note the correct fitting
position
❑ Engage onto both brake
calliper housing studs
and onto outer pad re‐
taining spring.
9 - Protective cap
❑ Pull on so that outer
sealing lip goes over
piston.
❑ Take care not to dam‐
age when inserting piston.
❑ Removing and installing ⇒ page 148
10 - Piston
❑ Removing and installing ⇒ page 147
❑ Apply a thin coating of assembly paste to the piston ⇒ Parts catalogue
11 - Sealing ring
❑ Take care not to damage when inserting piston.

146 Rep. gr.47 - Brakes - hydraulics

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

❑ Removing and installing ⇒ page 147

2.4 Removing and installing pistons for front

brake calliper
Special tools and workshop equipment required
♦ Thrust piece - T10145-

♦ Lever - U-30800 -

Note

These procedures are not applicable to the Brembo brake callip‐

ers.

2.4.1 Removing
– Expel the piston from the brake calliper housing by applying
compressed air.

Note

Place a piece of wood in the recess to prevent damage to the

piston.

2. Front brake calliper: repair 147

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Extract the join ring with the lever - U-30800 - .

Note

When removing ensure that the surface of the cylinder is not

damaged.

2.4.2 Installing
– The piston and join ring surfaces can only be cleaned using
alcohol and immediately dried.
– Before fitting the piston and seal ring, apply a thin coating of
assembly paste ⇒ Parts catalogue .
– Insert sealing ring in brake caliper housing.
– Place outer sealing lip of protective cap on the piston
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Insert the inside sealing lip into the groove of the cylinder using
the lever - U-30800- .

Note

When doing this hold piston in front of calliper housing.

– Insert piston with the thrust piece - T10145- in the brake cal‐
liper front.

Note

The outer sealing lip on the protective cap will then slip into the
piston groove.

148 Rep. gr.47 - Brakes - hydraulics

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

2.5 FNR G brake calliper (Model Leon 2009

Cupra and Cupra R): Assembly over‐
view
⇒ “2.6 Piston for FNR-G brake calliper (Leon 2009 Cupra and
Cupra R model): removal and installation”, page 150

Note

♦ When repairing, fit the whole repair unit.

1 - Protective cap
❑ Fit it over the bleed
valve
2 - Bleeder valve, 12 Nm
❑ Before tightening, lightly
grease the thread with
assembly paste (as‐
signment ⇒ Electronic
parts catalogue (ET‐
KA) ).
3 - Cover caps
❑ Fit onto the sleeve
4 - Guide pin, 30 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
5 - Sleeve bearing respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ Insert into brake caliper.

6 - Brake caliper
❑ Cannot be dismantled.
7 - Brake carrier
❑ Bolt onto brake caliper.
8 - Sealing ring
❑ Removing and installing
⇒ page 150
9 - Piston
❑ Removing and installing
⇒ page 150
❑ First apply a thin coating
of assembly paste (as‐
signment ⇒ Electronic
parts catalogue (ET‐
KA) ) to the pistons.
10 - Protective cap
❑ Removing and installing ⇒ page 150
❑ Take care not to damage when inserting piston.
11 - Retaining spring
❑ Note the correct fitting position
❑ Engage onto both brake calliper housing studs and onto outer pad retaining spring.

2. Front brake calliper: repair 149

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

2.6 Piston for FNR-G brake calliper (Leon

2009 Cupra and Cupra R model): re‐
moval and installation
Special tools and workshop equipment required
♦ Thrust piece - T10145-

♦ Lever - U-30800 -

♦ Assembly tool for protective caps - T10146-

2.6.1 Removing
– Loosen the bleed valve. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Note

To avoid damage to the piston, mount a wooden board to the

brake calliper.

– Press out the piston from the brake calliper using a com‐
pressed air gun -arrow-.

150 Rep. gr.47 - Brakes - hydraulics

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Extract the join ring with the lever - U-30800 - .

Note

When removing ensure that the surface of the cylinder is not

damaged.

2.6.2 Installing

Note

The surfaces of the piston and seal must be cleaned only with
methylated spirits and then dried.

– Before installation, apply a thin coating of assembly paste (as‐

signment ⇒ Electronic parts catalogue (ETKA) ) to the pistons
and seals.
– Insert the sealing ring in the brake calliper -arrow-.

Note

When doing this hold piston in front of calliper

Protected housing.
by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Insert protective cap -A- in the installation tool for protective

covers - T10146/1- -1-.

2. Front brake calliper: repair 151

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Press protective cap onto brake caliper so that seal is fitted

correctly all round using assembly tool -1- and piston resetting
tool -2-.
Check seat of protective cap:
– The protective cap of the brake calliper must not be able to be
removed by hand.

– Slightly press the piston against the cap using an extension

and a ratchet insert -1-. Fix the piston in this position.

Note

Keep piston straight to prevent damage to sealing collar.

– Use compressed air (max. 3 bar) -2- on the protective cap on

the brake calliper. The protective capProtected
jumpsbyover theCopying
copyright. piston for private or commercial purposes, in part or in whole, is not
when doing so. permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Press the piston into the brake calliper by hand. If necessary,

then use the thrust tool - T10145- .
The outer sealing lip will then spring into the piston groove.
– Close the bleeder valve.

152 Rep. gr.47 - Brakes - hydraulics

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

3 Rear brake caliper: repairs

⇒ “3.1 Rear brake calliper: assembly overview”, page 153
⇒ “3.2 Piston for rear brake caliper: removing and fitting”,
page 155
⇒ “3.3 Rear brake calliper ZOH 38 BIR III Bosch: assembly over‐
view”, page 158
⇒ “3.4 Piston for back brake calliper ZOH 38 BIR III Bosch: in‐
stallation and removal ”, page 160

3.1 Rear brake calliper: assembly overview

Note

♦ When carrying out repairs, install all parts supplied in repair

kit.
♦ New brake calipers are filled with brake fluid and are pre-bled.
♦ Apply a fine layer of assembly paste to the brake cylinder, the
piston and the seal ring ⇒ Parts catalogue . by copyright. Copying for private or commercial purposes, in part or in whole, is not
Protected
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ If repaired, the brake callipers must be bledrespect
before fitting
to the to the
correctness of information in this document. Copyright by SEAT S.A.
vehicle (without brake pads) ⇒ page 158 .

General overview, front-wheel drive vehicles:

3. Rear brake caliper: repairs 153

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

1 - Bolt, 35 Nm
❑ Self-locking
❑ Replace after each re‐
moval
❑ When loosening and
tightening, lock the
guide pin
2 - Air drain plug, 10 Nm
❑ Before tightening, apply
a fine layer of assembly
paste to the screw
thread ⇒ Parts cata‐
logue .
3 - Protective cap
4 - Guide pin
❑ Grease before fitting the
protective hood Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
5 - Protective cap respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ Fit to the brake plate and

to the guide pin
6 - Brake carrier with guide pin
(s) and protective cap
❑ Delivered as assembled
part, with sufficient
grease on the guide pins
❑ If the protective covers
or the guide pins are
damaged, then the re‐
pair kit must be fitted.
Use lubricant sachet
supplied to lubricate
guide pins.
7 - Protective cap
❑ Pull on so that outer
sealing lip goes over piston.
8 - Piston with automatic readjustment device
❑ Removing and installing ⇒ page 155
❑ Apply a thin coating of assembly paste to the piston ⇒ Parts catalogue
9 - Sealing ring
❑ Take care not to damage when inserting piston.
❑ Removing and installing ⇒ page 157
10 - Brake calliper housing with lever for the handbrake cable
❑ If the hand brake cable lever is not sealed, then replace the calliper housing.
❑ After repairing, carry out an initial purge on the brake calliper housing ⇒ page 158

General overview, four-wheel drive vehicles:

154 Rep. gr.47 - Brakes - hydraulics

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

1 - Brake calliper with lever for

the handbrake cable
❑ In the event of a leak in
the lever, the brake cal‐
liper should be replaced
❑ After repairing, the
brake calliper should be
bled ⇒ page 158
2 - Protective cap
3 - Bleed valve, 10 Nm
❑ Before tightening, lightly
grease the thread with
assembly paste ⇒ Parts
catalogue
4 - Hexagonal bolt, self-locking
- 35 Nm
❑ Renew.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ respect
When
permitted loosening
unless authorised and
by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

tightening, lock the

to the correctness of information in this document. Copyright by SEAT S.A.

guide pin
5 - Guide bolt with steps
❑ Shorter than that in Pos.
6
❑ Grease before fitting the
protective hood
6 - Guide pin
❑ Longer than that in Pos.
5
❑ Grease before fitting the
protective hood
7 - Protective cap
❑ Fit to the brake plate and
to the guide pin
8 - Brake plate with vibration damper
❑ Delivered as assembled part, with sufficient grease on the guide pins
❑ Fit the repair unit if protective hoods or guide bolts are damaged. Use the bag of grease attached to
grease the guide bolts
9 - Protective cap
❑ Pull on so that outer sealing lip goes over piston.
❑ Removing and installing ⇒ page 155
10 - Piston with automatic readjustment device
❑ Removing and installing ⇒ page 155
❑ Apply thin coat of assembly paste G 052 150 A2 to piston before installing.
11 - Sealing ring
❑ Removing and installing ⇒ page 155

3.2 Piston for rear brake caliper: removing

and fitting
Special tools and workshop equipment required

3. Rear brake caliper: repairs 155

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

♦ Lever - U-30800 -

♦ Opening/closing wrench - T10165-

3.2.1 Removing
– Open/close wrench - T10165- place on piston of the brake
calliper front.
– Extract the piston from the brake calliper housing by turning
the handle on the tool to the left.
♦ If piston will not move easily, a 13 mm open-end spanner can
be applied at the flats provided -arrow A-.

– Extract the join ring with the lever

Protected - U-30800
by copyright. - .for private or commercial purposes, in part or in whole, is not
Copying
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

156 Rep. gr.47 - Brakes - hydraulics

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

3.2.2 Installing
– The piston and join ring surfaces can only be cleaned using
alcohol and immediately dried.
– Before fitting the piston and seal ring, apply a thin coating of
assembly paste ⇒ Parts catalogue .
– Insert sealing ring in brake caliper housing.
– Fit the protective hood with the outer sealing lip over the piston.

– Insert the inside sealing lip into the groove of the cylinder using
the lever - U-30800- .

Note

When doing this hold piston in front of calliper housing.

– Open/close wrench - T10165- place on piston of the brake

calliper front.

– Use the plate to screw in the - T10165/1- piston.

– Fit the piston to the brake calliper housing by turning the han‐
dle on the tool to the right.

Note

♦ Insert rest and boring tool so that the collar lies on the brake
caliper.
♦ If the position of the piston is ended with the opening/closing
wrench - T10165- , the automatic adjuster of the brake caliper
breaks.

– Fit the brake pads.

3. Rear brake caliper: repairs 157

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

3.2.3 Pre-bleeding brake caliper

– Open the air purge bolt -arrow A- and, using the collection flask
- SAT 1175B/1 - , fill the brake fluid up to a point where fluid
without bubbles comes out of the screw hole (connection for
the brake hose) -arrow B- . Close the bleed screw.
– Close bleeder valve.

Note

For the initial purge, fit the brake calliper as shown in the illustra‐
tion.

3.3 Rear brake calliper ZOH 38 BIR III

Bosch: assembly overview
⇒ “3.4 Piston for back brake calliper ZOH 38 BIR III Bosch: in‐
stallation and removal ”, page 160

Note

♦ When carrying out repairs, install all parts supplied in repair

kit.
♦ New brake calipers are filled with brake fluid and are pre-bled.
♦ Apply a fine layer of assembly paste to the brake cylinder, the
piston and the seal ring ⇒ Parts catalogue .
If repaired, the brake callipers must be bled before fitting to the
♦permitted
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
vehicle (without brake pads) ⇒ page 158 .
respect to the correctness of information in this document. Copyright by SEAT S.A.

158 Rep. gr.47 - Brakes - hydraulics

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

1 - Brake calliper with lever for

the handbrake cable
❑ In the event of a leak in
the lever, the brake cal‐
liper should be replaced
❑ After repairing, the
brake calliper should be
bled ⇒ page 162
2 - Breather valve
❑ 10 Nm
❑ Before screwing in,
lightly grease the thread
with assembly paste ,
assignment ⇒ Electron‐
ic parts catalogue “ET‐
KA” .
3 - Protective cap
4 - Bolt
❑ 35 Nm
❑ Self-locking
❑ Renew.
❑ When loosening and
tightening, lock the
guide pin
5 - Guide pin (top)
❑ Grease before fitting the
protective hood
❑ Allocation ⇒ Electronic
parts catalogue “ETKA”
6 - Protective cap
❑ Fit onto brake carrier
and guide pin.
7 - Guide pin (bottom)
❑ With discharge groove
❑ Grease before fitting permitted
the protective hood
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
❑ Allocation ⇒ Electronic partsrespectcatalogue “ETKA”
to the correctness of information in this document. Copyright by SEAT S.A.

8 - Guide nozzle
❑ On the bottom guide bolts
9 - Brake carrier
❑ Delivered as assembled part, with sufficient grease on the guide pins
❑ Fit the repair unit if protective hoods or guide bolts are damaged. Use the bag of grease attached to
grease the guide bolts
❑ Allocation ⇒ Electronic parts catalogue “ETKA”
10 - Protective cap
❑ Pull on so that outer sealing lip goes over piston.
❑ Removing and installing ⇒ page 160
11 - Piston with automatic readjustment device
❑ Removing and installing ⇒ page 160
❑ Before installation, apply a thin coating of assembly paste , assignment ⇒ Electronic parts catalogue
“ETKA” to the pistons.
12 - Sealing ring
❑ Removing and installing ⇒ page 160

3. Rear brake caliper: repairs 159

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

3.4 Piston for back brake calliper ZOH 38

BIR III Bosch: installation and removal
Special tools and workshop equipment required
♦ Lever - U-30800 -

♦ Opening/closing wrench - T10165-

3.4.1 Removing
– Open/close wrench - T10165- place on piston of the brake
calliper front.
– Extract the piston from the brake calliper housing by turning
the handle on the tool to the left.
♦ If piston will not move easily, a 13 mm open-end spanner can
be applied at the flats provided -arrow A-.

160 Rep. gr.47 - Brakes - hydraulics

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Extract the join ring with the lever - U-30800 - .

3.4.2 Installing
– The piston and join ring surfaces can only be cleaned using
alcohol and immediately dried.
– Before fitting the piston and seal ring, apply a thin coating of
assembly paste ⇒ Parts catalogue
Protected . Copying for private or commercial purposes, in part or in whole, is not
by copyright.

– Insert sealing ring in brakerespect

permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
caliper
to thehousing.
correctness of information in this document. Copyright by SEAT S.A.

– Fit the protective hood with the outer sealing lip over the piston.

– Insert the inside sealing lip into the groove of the cylinder using
the lever - U-30800- .

Note

When doing this hold piston in front of calliper housing.

– Open/close wrench - T10165- place on piston of the brake

calliper front.

3. Rear brake caliper: repairs 161

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Use the plate to screw in the - T10165/1- piston.

– Fit the piston to the brake calliper housing by turning the han‐
dle on the tool to the right.

Note

♦ Insert rest and boring tool so that the collar lies on the brake
caliper.
♦ If the position of the piston is modified with the piston extractor
tool then the automatic readjustment of the brake calliper will
be broken.

– Fit the brake pads.

3.4.3 Pre-bleeding brake caliper

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Open the air purge bolt -arrow A- and, using the collection flask
- SAT 1175B/1 - , fill the brake fluid up to a point where fluid
without bubbles comes out of the screw hole (connection for
the brake hose) -arrow B- . Close the bleed screw.

Note

For the initial purge, fit the brake calliper as shown in the illustra‐
tion.

162 Rep. gr.47 - Brakes - hydraulics

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

4 Bleeding brake system

Caution

Please strictly follow the bleeding procedure of the brake sys‐

tem described in the present section.

Note

♦ Do not mix the brake fluid with liquids containing mineral oils
(oil, petrol, detergents) for any reason. Mineral oils damage
the seals and sleeves in the brake system.
♦ The syphoned (used) brake fluid can not be re-used.
♦ Only use original, unused brake fluid according to the standard
US FMVSS 116 DOT 4, ⇒ Spare parts catalogue .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Brake fluid is poisonous. Also due to its corrosive effect brake
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with

fluid must not come into contact with paintwork.

respect to the correctness of information in this document. Copyright by SEAT S.A.

♦ Brake fluid is hygroscopic, which means it absorbs moisture

from the ambient air and should therefore always be stored in
air-tight containers.
♦ Clean any spilled brake fluid with large amounts of water.
♦ Observe environmental requirements for disposal.
♦ The warning lamp of the brake system lights up steadily or
blinks (depending on the version) if the brake liquid level is too
low or if a fault is present in the ABS/ESP system or in the
handbrake.

WARNING

If the brake fluid is topped up with the brake bleeder - SAT

1175B- , take care that the filling pressure does not exceed the
following values specified.
If the filling pressure given is exceeded, a change-over valve
for EDS control with hydraulic increase prevents a complete
purging of the areas specific to the EDS in the control unit of
the brake system. In this case, complete bleeding of the brake
system is not guaranteed.

Adjusting the pressure of the brake bleeder - SAT 1175B-

Note

Consider the ⇒ operating instructions of the brake bleeder - SAT

1175B-

Before proceeding with the bleeding tasks, adjust the pressure of

the brake bleeder - SAT 1175B- according to the control unit of
the brake system installed in the vehicle.
♦ Mark 60 / Mark 70: 1 bar

4. Bleeding brake system 163

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

Caution

Only perform the pre-bleeding if one of the chambers of the

brake liquid container is completely empty (e.g. if the brake
system shows leaks or after replacing the control unit of the
brake system).
If no chamber of the brake liquid container is empty, bleed the
system directly according to the instructions in ⇒ page 165 .

4.1 Initial purge

Special tools and workshop equipment required
♦ Brake de-airing device - SAT 1175B -

♦ Vehicle diagnosis device

– Connect the brake bleeder - SAT 1175B - . Consider the ⇒
operating instructions of the brake bleeder - SAT 1175B - .
– Adjust the pressure of the brake bleeder - SAT 1175B- ac‐
cording to the control unit of the brake system installed in the
vehicle. Refer to ⇒ page 163 .
– Remove the protective cap -1- of the bleeder screws of the
brake callipers of the front axle.

Note

Mount the hose of the collector bottle - SAT 1175B/1- accurately

on the bleeder screws so that no air enters the connection.

164 Rep. gr.47 - Brakes - hydraulics

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Connect the hose -1- of the collector bottle - SAT 1175B/1- to

the bleeder screws of the brake calliper on the front axle.
– Open the bleeding bolts.
– Leave the bleeding bolts open and only close when brake liq‐
uid appears without any air bubbles.
– Remove the hose of the collector bottle - SAT 1175B/1- and
place a protective cap on a bleeding bolt of the brake calliper.
– Tighten the bleeding bolts to the specified tightening torque.
See ⇒ page 168
– After carrying out the operations described above, bleed the
brake calliper / cylinder of the rear axle.
– Using the vehicle diagnosis device , bleed the control unit of
the brake system according to the instructions ⇒ page 11 .
– After ending the procedure using the vehicle diagnosis device ,
switch off the ignition and disconnect the diagnostic connector.
– Continue according to the instructions of section
⇒ page 165 .

4.2 Bleeding the brake

Protected system
by copyright. with
Copying for private the
or commercial purposes, in part or in whole, is not
brake bleederrespect
- SAT 1175B -
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
to the correctness of information in this document. Copyright by SEAT S.A.

Special tools and workshop equipment required

♦ Brake de-airing device - SAT 1175B -

– Connect the brake bleeder - SAT 1175B - . Consider the ⇒

operating instructions of the brake bleeder - SAT 1175B - .
– Adjust the pressure of the brake bleeder - SAT 1175B- ac‐
cording to the control unit of the brake system installed in the
vehicle. Refer to ⇒ page 163 .

Caution

If one of the chambers in the brake liquid container is com‐

pletely empty, also bleed the coupling system of the vehicle.
For this purpose the instructions in ⇒ Rep. gr. 30 ; clutch re‐
lease, cylinder: repair complying with the gear instructions of
the gears housed in the vehicle.

4. Bleeding brake system 165

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– If installed, remove the protective caps -1- of the four bleeder

screws of the brake calliper / cylinder.

Note

Mount the hose of the collector bottle - SAT 1175B/1- accurately

on the bleeder screws so that no air enters the connection.

– Connect the hose -1- of the collector bottle - SAT 1175B/1- to

each of the bleeder screws of the brake calliper and open ac‐
cording to the sequence described above:
1- Rear right brake calliper / cylinder.
2- Rear left brake calliper / cylinder.
3- Front right brake calliper.
4- Front left brake calliper.
– Leave the bleeding bolts open and only close when brake liq‐
uid appears without any air bubbles.

– Remove the hose of the collector bottle - SAT 1175B/1- and

at the same time place a protective cap -1- on a bleeding bolt
of the brake calliper / brake cylinder.
– Tighten the bleeding bolts to the specified tightening torque.
See ⇒ page 168

Note

Fill up the brake liquid container only to the -MAX- mark.

166 Rep. gr.47 - Brakes - hydraulics

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

4.3 Bleeding the brake system without the

brake bleeder - SAT 1175B-

Caution

If one of the chambers in the brake liquid container is com‐

Note

To carry out the post-bleeding, the aid of a second mechanic is

required

– If installed, remove the protective caps -1- of the four bleeder

screws of the brake calliper / cylinder.

Note

Mount the hose of the collector bottle - SAT 1175B/1- accurately

on the bleeder screws so that no air enters the connection.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Beginning with the right rear wheel, connectrespect
the bleeding hose
to the correctness of information in this document. Copyright by SEAT S.A.
-1- of the collecting bottle - SAT 1175B/1- to the bleeder screw
of the brake calliper / cylinder. Do not loosen the bolt yet.
– Keep pressing the brake pedal controlled for building up the
pressure in the cycle.
– Press the brake pedal with force and maintain pressure while
the second mechanic opens the bleeder screw, to which the
collecting bottle - SAT 1175B/1- is connected.
– Close the bleeder screw if the brake pedal reaches the end of
its pedal travel. Then slowly loosen the brake pedal
– Repeat the two operations described above until it is observed
that the brake fluid appears without air bubbles.

4. Bleeding brake system 167

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Remove the hose of the collecting bottle - SAT 1175B/1- and

attach the protective cap -1- of the bleeding bolt.
– Tighten the bleeding bolt with the specified tightening torque.
See ⇒ page 168
– Continue with the bleeding of the brake callipers / cylinders of
the remaining three wheels. Repeat the operations described
above, taking into consideration of the following listed se‐
quence:
♦ Rear left brake calliper / cylinder.
♦ Front right brake calliper.
♦ Front left brake calliper.

Note

Fill up the brake liquid container only to the -MAX- mark.

– Check the liquid level in the brake liquid container and fill the
liquid when necessary.
– When the engine is running, check the pedal travel and the
resistance of the brake pedal.
• If the brake pedal demonstrates excessive pedal travel or an
unusual resistance: check if there is any leakage in the pres‐
sure bleeder and carry out the ventilation process as
⇒ page 167 described.
• If the pedal travel and resistance of brake pedals is normal:
carry out a test run with the vehicle and produce a ABS control
cycle as a minimum.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
4.4 Specified torques permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

Designation Tightening torque (Nm)

Bleeder screw 10

4.5 Replace brake fluid

⇒ Maintenance ; Booklet 101 ; Precision maintenance; Descrip‐
tion of work; Brake fluid: replacement

168 Rep. gr.47 - Brakes - hydraulics

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

5 Brake servo and brake master cylin‐

der
⇒ “5.1 Brake servo/brake master cylinder, LL: Assembly over‐
view”, page 169
⇒ “5.2 Brake servo/brake master cylinder, RL: Assembly over‐
view”, page 171
⇒ “5.3 Vacuum pump for brake servo: removal and installation”,
page 173
⇒ “5.4 Checking non-return valve”, page 176
⇒ “5.5 Removing and installing vacuum pump for brakes V192 ”,
page 176
⇒ “5.6 Removing and installing brake master cylinder”,
page 177
⇒ “5.7 Removing and installing brake servo”, page 179

5.1 Brake servo/brake master cylinder, LL:

Assembly overview

Note

♦ The master brake cylinder and the servo brake can be re‐
placed independently.
♦ Use only new brake fluid. The instructions shown on the fluid
tank should be observed.

5. Brake servo and brake master cylinder 169

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

1 - Pedal cluster
2 - Self-locking hexagon nut,
25 Nm
❑ Replace after each re‐
moval
3 - Seal
❑ For brake servo.
4 - Brake servo
❑ In petrol engines the
vacuum required is tak‐
en from the intake mani‐
fold.
❑ Some vehicles with pet‐
rol engines and auto‐
matic gearboxes are fit‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
ted with a brake vacuum respect to the correctness of information in this document. Copyright by SEAT S.A.
pump - V192-
⇒ page 176
❑ Vehicles with reinforced
hydraulic servo brake
(HBV) are fitted with a
servo brake vacuum
sender - G483-
⇒ Item 6 (page 170)
❑ In diesel engines the
vacuum is obtained by a
fitted vacuum pump
⇒ page 173
❑ Functional check:
– With engine off, press
the brake pedal hard
several times (this re‐
duces the existing vac‐
uum in the servo brake).

– Next, keep the brake

pedal depressed halfway and start engine. If the brake servo is functioning properly, the brake pedal will
be felt to go down as the servo takes effect.
❑ If faulty, renew as a complete unit.
❑ Separating from the brake pedal ⇒ page 140
❑ Removing and installing ⇒ page 179
5 - Sealing ring
6 - Servo brake vacuum sender - G483-
❑ Only in vehicles fitted with HBV (reinforced hydraulic servo brake)
❑ Removing and installing ⇒ page 33
7 - Brake master cylinder without brake light switch
❑ Allocation: ⇒ Parts catalogue
❑ Cannot be repaired. If faulty, renew as a complete unit.
❑ Removing and installing ⇒ page 177
8 - Master brake cylinders with brake pedal position sender - G100-
❑ Allocation: ⇒ Parts catalogue
❑ Cannot be repaired. If faulty, renew as a complete unit.
❑ Removing and installing ⇒ page 177
9 - Brake pedal position sender - G100-
❑ Brake pedal switch - F47- inclusive

170 Rep. gr.47 - Brakes - hydraulics

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

❑ In vehicles manufactured prior to week 45/05, the brake light switch - F- is located on the brake pedal
⇒ page 28
❑ Removing and installing ⇒ page 28
10 - Torx screw 5 Nm
11 - Heat shield
12 - Self-locking hexagon nut, 25 Nm
❑ Replace after each removal
13 - Brake line, 14 Nm
❑ From secondary piston circuit of brake master cylinder to hydraulic unit.
14 - Brake line, 14 Nm
❑ From primary piston circuit of brake master cylinder to hydraulic unit.
15 - Seal cap
❑ Moisten with brake fluid and place the brake fluid reservoir under pressure
16 - Brake fluid reservoir
17 - Plug
18 - Seal cap
❑ Vacuum hose connection
19 - Vacuum hose
❑ Fit in brake servo.

Check the interior servo brake cover

– Remove the lower trim of the driver's side foot well ⇒ Body‐
work, interior work; Rep. gr. 68 ; Stowage compartment,
coverings and trims .
– Ensure that the protection has not come out of the perimeter
groove as shown in the illustration.

5.2 Brake servo/brake master cylinder, RL:

Assembly overview

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
♦ The master brake cylinder and the servo brake can be re‐
respect to the correctness of information in this document. Copyright by SEAT S.A.
placed independently.
♦ Use only new brake fluid. The instructions shown on the fluid
tank should be observed.

5. Brake servo and brake master cylinder 171

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

1 - Pedal cluster
2 - Bolt, 25 Nm
3 - Self-locking nut: 25 Nm
❑ Replace after each re‐
moval
4 - Seal
❑ For brake servo.
5 - Brake servo
❑ In petrol engines the
vacuum required is tak‐
en from the intake mani‐
fold.
❑ Some vehicles with pet‐
rol engines and auto‐
matic gearboxes are fit‐
ted with a brake vacuum
pump - V192-
⇒ page 176
❑ Vehicles with reinforced
hydraulic servo brake
(HBV) are fitted with a
servo brake vacuum
sender - G483-
⇒ Item 6 (page 170)
❑ In diesel engines the
vacuum is obtained by a
fitted vacuum pump
⇒ page 173
❑ Functional check:
– With engine off, press
the brake pedal hard
several times (this re‐
duces the existing vac‐
uum in the servo brake).

– Next, keep the brake pedal depressed halfway and start engine. If the brake servo is functioning properly,
the brake pedal will be felt to go down as the servo takes effect.
❑ If faulty, renew as a complete unit.
❑ Separating from the brake pedal ⇒ page 140
❑ Removing and installing ⇒ page 179
6 - Sealing ring
7 - Servo brake vacuum sender - G483-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Only in vehicles fitted with HBV (reinforced
permitted hydraulic servo
unless authorised brake)
by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
❑ Removing and installing ⇒ page 33
8 - Brake master cylinder
❑ After week 45/ 05 with brake light switch - F-
❑ In vehicles manufactured prior to week 45/05, the brake light switch - F- is located on the brake pedal
⇒ page 28
❑ Allocation: ⇒ Parts catalogue
❑ Cannot be repaired. If faulty, renew as a complete unit.
❑ Removing and installing ⇒ page 177

172 Rep. gr.47 - Brakes - hydraulics

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

9 - Heat shield
10 - Nut, 50 Nm
11 - Bolt, 25 Nm
12 - Brake line, 14 Nm
❑ From secondary piston circuit of brake master cylinder to hydraulic unit.
13 - Torx screw 5 Nm
14 - Brake pedal position sender - G100-
❑ In vehicles manufactured prior to week 45/05, the brake light switch - F- is located on the brake pedal
⇒ page 28
❑ Removing and installing ⇒ page 28
15 - Seal cap
❑ Moisten with brake fluid and place the brake fluid reservoir under pressure
16 - Brake line, 14 Nm
❑ From primary piston circuit of brake master cylinder to hydraulic unit.
17 - Brake fluid reservoir
18 - Plug

5.3 Vacuum pump for brake servo: removal

and installation

5.3.1 Vacuum pump for brake servo for 4 cyl‐

inder diesel motors (2 valve) : removal
and installation
Removing Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
– Must not be dismantled. respect to the correctness of information in this document. Copyright by SEAT S.A.

Tandem pump -1- (vacuum pump and fuel pump)

– Disconnect the vacuum hose -2- from the brake servo together
with the retention valve.
Fuel pipes -3 and 4-.
– Remove tandem pump ⇒ 4-cyl.-diesel motor (2-valve); Rep.
gr. 20 ; Components of fuel delivery: removal and installation .
Installing
Install in reverse order.

5. Brake servo and brake master cylinder 173

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

5.3.2 Vacuum pump for brake servo for 4 cyl‐

inder diesel motors (4 valve) : removal
and installation
Removing
– Must not be dismantled.
Tandem pump -4- (vacuum pump and fuel pump)
– Disconnect the vacuum hose -1- from the brake servo together
with the retention valve.
Fuel pipes -2 and 3-.
– Remove tandem pump ⇒ 4-cyl.-diesel motor (4-valve); Rep.
gr. 20 ; Components of fuel delivery: removal and installation .
Installing
Install in reverse order.

5.3.3 Vacuum pump for brake servo for 4 cyl‐

inder petrol motor, BYT-BZB: removal
and installation
Removing
– Remove the air filter body, the bleeding hose and the air flow
hoses ⇒ Airfilter: removal and installation; Rep. gr. 24 .
– Remove high pressure pump ⇒ mixture preparation, injection,
E-Gas; Rep. gr. 24 ; Injection; high pressure pump: removal
and installation
– Disconnect the vacuum hose from the vacuum pump -1- and
place to one side.
– Undo the nut -2- and remove the earth cable.
– Remove the coolant pipe upwards.

– Undo the bolts -arrows- and remove the vacuum pump.

Installing
Install in reverse order.

174 Rep. gr.47 - Brakes - hydraulics

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

5.3.4 Vacuum pump of brake servo for com‐

mon rail motors: removal and installa‐
tion

DANGER!

The vacuum pump must never be removed as the function of

the vacuum part may be influenced. This would result in dam‐
age to the servo brake.

– Dismount the air filter casing together with the air mass meter
and the connecting pipe ⇒ 4 cylinder diesel engine. (1.6 l 4V,
TDI Common Rail); Rep. gr. 23 ; Air filter .
– Pull vacuum line -1- off vacuum pump -2-.

– Unscrew the screw that retains the supercharger air pipe

permitted -2 and 5- and by -arrows- andS.Amove
does notas far away asanypossible
liability withuntil
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
unless authorised SEAT S.A. SEAT guarantee or accept
the rear
respect screw connection
to the correctness of information in of
thisthe vacuum
document. pump
Copyright by SEATcan
S.A.be ac‐
cessed.

– Unscrew the fixing bolts of the vacuum pump -arrows-.

– Remove the vacuum pump -2- from the cylinder head.
Installing
For fitting, the operations are carried out in reverse order to the
removal, taking the following into account:

Note

♦ Make sure that the coupling of the vacuum pump has been
mounted on the camshaft correctly.
♦ Replace the vacuum pump seals.

– Install the vacuum pump and tighten the bolts to 10 Nm.

– Connect the vacuum line of the brake servo to the vacuum
pump -1-.

5. Brake servo and brake master cylinder 175

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

5.4 Checking non-return valve

♦ The valve -A- must allow air to pass in the direction shown by
the arrow.
♦ Valve must remain closed in opposite direction.
– Make sure it is fitted in the correct position.

5.5 Removing and installing vacuum pump

for brakes - V192 -
The brake vacuum pump - V192 - is located on the front of the
automatic gearbox, in the direction of travel.
The brake vacuum pump - V192 - is not designed to be repaired.
If there is a fault, the brake vacuum pump - V192 - must be re‐
placed.
This can be checked in “Guided Fault Finding” with the vehicle
diagnostic tester .

5.5.1 Removing
– Remove the vacuum hose -1- of the brake vacuum pump -
V192 - .
– Disconnect the connector -2- of the brake vacuum pump -
V192 - .
– Remove the connectors and remaining pipes from the bracket
-3-.
– Unscrew the bolts -arrows- from the bracket -3- with the brake
vacuum pump - V192 - .

– Then unscrew the bolts -arrows- for the brake vacuum pump
- V192- -1- from the bracket -2-.

5.5.2 Installing
Install in reverse order.
Specified torques:
Brake vacuum pump - V192- to bracket 8 Nm
Bracket on the automatic gearbox 25 Nm

176 Rep. gr.47 - Brakes - hydraulics

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

5.6 Removing and installing brake master

cylinder
Special tools and workshop equipment required
♦ Brake de-airing device - SAT 1175B -

♦ Thrust piece - U 30042-

5.6.1 Removing
– Remove engine cover ⇒ Maintenance Protected
; Booklet 1 . Copying for private or commercial purposes, in part or in whole, is not
by copyright.
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Diesel engine vehicles: respect to the correctness of information in this document. Copyright by SEAT S.A.

– Remove the air filter body, the bleeding hose and the air flow
hoses ⇒ Air filter: disassemble and assemble; Rep. gr. 23 .
Vehicles with petrol engine:
– Remove the air filter body, the bleeding hose and the air flow
hoses ⇒ Air filter: disassemble and assemble; Rep. gr. 24 .
– Note or request radio code on vehicles with coded radio if
necessary.
– Remove battery ⇒ Electrical system; Rep. gr. 27 ; Battery
– Remove battery tray -arrows- and remove from vehicle.
– For protection against any leak of brake fluid, cover the zone
under the brake master cylinder with enough lint-free cloths.
– Suck as much of the brake fluid from the brake fluid tank as
possible using the brake bleeder - SAT 1175B - .
Vehicles with manual gearbox:

5. Brake servo and brake master cylinder 177

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Clamp the return hose for the clutch master cylinder -B-with
the clamping tool - U-30042 - .
– Remove the return hose -B- for the clutch master cylinder.
All vehicles (continued):
– Unplug the connector -A- for the brake system indicator sen‐
sor.
– Remove the plug of the brake pedal position sender - G100-
(only in vehicles manufactured from week 45/05).
– To remove the brake fluid tank press outwards on the insertion
tabs and pull on the tank to remove it from the securing caps.

– Unscrew the brake pipes -1- from the brake master cylinder
and seal them with the plugs from the repair kit ⇒ Parts cata‐
logue .
– Unscrew nuts -2- from brake master cylinder.
– If fitted, remove the thermal protection plate with the retention
plate.
– Remove the servo brake master cylinder.

5.6.2 Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:
– Replace the seal ring between the brake master cylinder and
the servo brake.
– When fitting the brake master cylinder, ensure that the control
rod in the servo brake seats correctly.
– Press a little on the brake pedal; this will make it easier to insert
the master cylinder onto the control rod.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Bleeding air from the brake system ⇒ page 163 .
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Purging air from the clutch hydraulic system ⇒ 5 speed man‐
ual gearbox; Rep. gr. 30 ; Hydraulic system: removing and
fitting
– For those vehicles with ABS/ESP begin the basic adjustment
for the braking pressure sender(s).
Use vehicle diagnosis device ⇒ Vehicle diagnostic tester for this
purpose.
– Carry out a test run and the ESP operation test.
Use vehicle diagnosis device for this purpose.
– Connect the vehicle diagnosis device to the vehicle adapter
and then select the function test in “Function/Component se‐
lection” ⇒ page 11 .
– Then:
– “Running gear”
– “Brake system”
– “01 - Self-diagnosis systems Mark 60/Mark 70”
– “03 - ABS/EDS/ASR/ESP Mark 60/Mark 70”

178 Rep. gr.47 - Brakes - hydraulics

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– “Functions”
– “ESP test drive”

5.6.3 Specified torques

Component Nm
Battery tray to body 10

5.7 Removing and installing brake servo

5.7.1 Removing
– Reduce the pressure in the servobrake by pressing on the
brake pedal several times.
– Remove the master brake cylinder ⇒ page 177 .
– Release the vacuum tube from the servo brake and remove it.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Separate connectors of the servo
permitted unless authorised by SEATbrake,
S.A. SEATifS.A
there are
does not any. or accept any liability with
guarantee
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Remove the lower trim of the driver's side foot well ⇒ Body‐
work, interior work; Rep. gr. 68 ; Stowage compartment,
coverings and trims .

Note

After week 45/05 the brake light switch on the support block does
not exist.

– Remove the brake light switch ⇒ page 28 .

– Separate the brake pedal from the servo brake ⇒ page 140 .

– Unscrew nuts -1-.

– Remove the servo brake.

5.7.2 Installing
Carry out installation in the reverse sequence, noting the follow‐
ing:

Note

A second mechanic will be needed to position the servo brake to

the brake pedal bracket.

– Secure the brake pedal to the servo brake.

– Fitting the master cylinder ⇒ page 178 .

5. Brake servo and brake master cylinder 179

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Purge the air from the brake system: ABS/ESP Mark 60

⇒ page 163 .
– Purging air from the clutch hydraulic system ⇒ 5 speed man‐
ual gearbox; Rep. gr. 30 ; Hydraulic system: removing and
fitting
– For those vehicles with ABS/ESP begin the basic adjustment
for the braking pressure sender(s) ⇒ Vehicle diagnostic tester .
– For those vehicles fitted with ABS/ESP Mark 60, make the test
run for the ESP.
Use vehicle diagnosis device ⇒ Vehicle diagnostic tester for this
purpose.

180 Rep. gr.47 - Brakes - hydraulics

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

6 Brake pipes and brake hoses:

6.1 Removing and installing brake lines and

brake hoses
⇒ “6.1.1 Brake pipes on the master brake cylinder”, page 181
⇒ “6.1.2 Brake pipes to the hydraulic unit”, page 181
⇒ “6.1.3 Brake pipes/hoses on the front wheels”, page 182
⇒ “6.1.4 Brake hose connection with anti-twist protection”,
page 182
⇒ “6.1.5 Brake pipe connection on the brake calliper”, page 182
⇒ “6.1.6 Brake pipe connections on the underbody of the vehicle”,
page 182
⇒ “6.1.7 Brake pipes / rear axle hoses”, page 183
⇒ “6.1.8 Brake pipe coupling”, page 183
Now, the different fitting positions will be shown along with the
brake pipe and hose tightening torques.

6.1.1 Brake pipes on the master brake cylin‐

der
1 - Brake pipes to the master brake cylinder - 14 Nm.

6.1.2 Brake pipes to the hydraulic unit

1 - Brake pipes to the hydraulic unit - 14 Nm.

6. Brake pipes and brake hoses: 181

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

6.1.3 Brake pipes/hoses on the front wheels

1 - 8 Nm hexagonal bolt.
2 - Brake hose, 14 Nm
3 - Retention pin.

6.1.4 Brake hose connection with anti-twist

protection
Ensure that the groove in the ring tube of the hose is adjusted to
the locking projection -arrow-.

6.1.5 Brake pipe connection on the brake cal‐

liper
♦ Brake hose -2-: 14 Nm
♦ Hexagonal bolt -3-: 15 Nm

6.1.6 Brake pipe connections on the under‐

body of the vehicle
1 - Brake hose, 14 Nm

182 Rep. gr.47 - Brakes - hydraulics

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

6.1.7 Brake pipes / rear axle hoses

1 - Brake hose, 14 Nm
2 - Retention pin.

6.1.8 Brake pipe coupling

– When tightening banjo bolt -2-, counter-hold on banjo nut -1-.
♦ Specified torque: 14 Nm.

6. Brake pipes and brake hoses: 183

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

7 Brake pipe repairs

⇒ “7.1 Flaring tool: assembly survey”, page 186
⇒ “7.2 Work instructions”, page 186
Using the pipe seam tool - VAS 6056- the brake pipes with an
exterior diameter of 5 mm may be re-edged without damaging the
covering. In certain cases, this allows sections of brake lines to
be renewed at less expense.
The V.A.G. 1356 edge cutting equipment cannot be used due to
the covering and diameter of the black brake pipes.

Note

♦ The brake pipes can only be bent to a maximum of 90º, oth‐

erwise they will rupture and be deformed with a reduction in
the acceptable tube diameter.
♦ The brake lines should preferably be cut at some point on the
underside of the vehicle.
♦ Choose the position of the intermediate elements so that they
do not rub on mobile elements.
♦ Do not lubricate the edge cutting spindle, use alcohol to clean
it.

Special tools and workshop equipment required

♦ Flanging tool - VAS 6056-

♦ Brake de-airing device - SAT 1175B -

List of individual tools:

184 Rep. gr.47 - Brakes - hydraulics

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

1 - Flanging tool - VAS 6056/1-

❑ On the edging tool - VAS
6056/1- the tube cutters
- VAS 6056/2- are inclu‐
ded.
2 - Pipe cutter - VAS 6056/2-
3 - Peeler - VAS 6056/3-
❑ The headless bolts (on
the rod and on the side)
are adjusted and their
position should not be
modified.
4 - Clamps - VAS 6056/4-
5 - Bending machine - VAS
6056/5-
6 - Special wrench, 6 mm
7 - Clamps - VAS 6056/7-

7. Brake pipe repairs 185

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

7.1 Flaring tool: assembly survey

1 - Top part of the edge cutting

spindle
❑ Screwdriver for chang‐
ing the edging clamps
2 - Sleeve attachment
❑ This must be unscrewed
to access the attach‐
ment bolt for the upper
section.
3 - Securing bolt
❑ For the upper section of
the edging tool.
4 - Headless bolts for the edg‐
ing clamps
❑ Centre and secure the
edging clamps
❑ Hexagon socket, 2 mm
5 - Clamps
❑ Different versions
❑ Installation instructions
⇒ page 186

Edging clamp installation instructions:

♦ VAS 6056/6 (dark) for black brake lines
♦ VAS 6056/7 (light) for green brake lines

Note

The arrow on the round section of the clamps should point to‐
wards the edge of the housing and the straight side should face
the spindle,
Protectedotherwise the edge
by copyright. Copying willornot
for private be correctly
commercial purposes, informed.
part or in whole, is not
permitted unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
respect to the correctness of information in this document. Copyright by SEAT S.A.

7.2 Work instructions

– Unscrew the corresponding pipe of the brake calliper or the
brake cylinder, collect the brake fluid that flows and dispose of
according to legislation.

186 Rep. gr.47 - Brakes - hydraulics

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Cut the pipe in a suitable location (straight, accessible section)

using the tube cutters -2-.
– Remove the section to be replaced.
– Lubricate the brake pipe surface.

– Fasten brake line between clamping jaws -4- so that it extends

approx. 50 mm beyond the jaws.
– Secure the peeling tool -3- in a drill and fit to the brake pipe.
– Using low-speed and applying little pressure against the pipe,
peel the covering.
The section that must be peeled is defined by the stop on the tool.
– Remove the tool from the brake pipes along with any residue
of coating.

– Remove the clamps and insert the pipe into the pipe bolt -D-.

– Insert the brake pipe -B- into the edging tool as far as possible
-A-.

Note

When the Allen bolts are tightened the brake pipe should touch
the stop, otherwise the edge will not be done correctly.

– Put an initial tension on the pipe (by gently tightening the bolts)
on the edging tool until it cannot be moved. Lift the stop -A-
and tighten the Allen bolts with the elbow joint screwdriver
-C-.

7. Brake pipe repairs 187

Altea 2004 ➤ , Altea 2009 ➤ , Altea XL 2007 ➤ , Altea XL 2009 ➤ , Alte ...
Brake system - Edition 03.2015

– Rotate the spindle completely on the edging tool.

– Rotate the spindle in the opposite direction.
– Unscrew hexagon socket head bolts in diagonal sequence.
– Remove the pipes from the edging tool, clean and check the
brake pipe and complete edge.
Briefly clean the section of brake pipe on the vehicle:
– Connect the brake bleeder, - SAT 1175B - connecting the hose
of the suction bottle - SAT 1175B/1- to the pipe edge and op‐
erate the brake bleeder - SAT 1175B - until brake fluid flows.
– Clean the brake pipe once more using compressed air.

– Join the brake pipes using a coupling -E-.

– Fit the pipes.
– Bleeding air from the brake system ⇒ page 163 .

188 Rep. gr.47 - Brakes - hydraulics

VW Touran 2003 Brake Systems Eng
100% (1)
VW Touran 2003 Brake Systems Eng
168 pages
SM 7
100% (1)
SM 7
398 pages
2017 - VW Passat b8 Arteon Brake System Eng PDF
100% (1)
2017 - VW Passat b8 Arteon Brake System Eng PDF
160 pages
Brake System
No ratings yet
Brake System
145 pages
VW Atlas - Brake System
No ratings yet
VW Atlas - Brake System
101 pages
D3E804FD617-Brake System
No ratings yet
D3E804FD617-Brake System
197 pages
All Audi Repair and Service Manuals
100% (1)
All Audi Repair and Service Manuals
154 pages
2017 Atlas Brakes
No ratings yet
2017 Atlas Brakes
117 pages
Seat Leon 3 Brake System Eng
100% (2)
Seat Leon 3 Brake System Eng
204 pages
Service: Touran 2003
No ratings yet
Service: Touran 2003
168 pages
Audi A4 A5 Brake System Eng
No ratings yet
Audi A4 A5 Brake System Eng
242 pages
SM 13
No ratings yet
SM 13
216 pages
Brake Systems
No ratings yet
Brake Systems
226 pages
GTI D4B80277FA9-Brake - System
No ratings yet
GTI D4B80277FA9-Brake - System
170 pages
Service: Audi A4 2008 Audi A5 Cabriolet 2009 Audi A5 Coupé 2008
No ratings yet
Service: Audi A4 2008 Audi A5 Cabriolet 2009 Audi A5 Coupé 2008
242 pages
VW Passat b6 Brake Systems Eng
No ratings yet
VW Passat b6 Brake Systems Eng
93 pages
Brake System
No ratings yet
Brake System
160 pages
D4B804B24F7 Brake System
No ratings yet
D4B804B24F7 Brake System
159 pages
Skoda Octavia 3 Brake Systems Eng
No ratings yet
Skoda Octavia 3 Brake Systems Eng
164 pages
SM 33 PDF
No ratings yet
SM 33 PDF
101 pages
Audi A4-6
No ratings yet
Audi A4-6
187 pages
Brake System
No ratings yet
Brake System
152 pages
Audi q5 2008 Brake System Eng
No ratings yet
Audi q5 2008 Brake System Eng
213 pages
Audi A3 2013 Brake System Eng
No ratings yet
Audi A3 2013 Brake System Eng
249 pages
Skoda Kodiaq Brake System Eng
No ratings yet
Skoda Kodiaq Brake System Eng
132 pages
VW Golf 6 Brake System Eng
No ratings yet
VW Golf 6 Brake System Eng
139 pages
Brake Systems
No ratings yet
Brake Systems
132 pages
SM 16
No ratings yet
SM 16
218 pages
VW Polo 5 2010 Brake Systems Eng
No ratings yet
VW Polo 5 2010 Brake Systems Eng
151 pages
D4B806878F3-Brake System
No ratings yet
D4B806878F3-Brake System
212 pages
Skoda Yeti Brake Systems Eng
No ratings yet
Skoda Yeti Brake Systems Eng
174 pages
Polo Brake Systems
No ratings yet
Polo Brake Systems
132 pages
Brake Systems7P
No ratings yet
Brake Systems7P
109 pages
D3E800A4763-Brake System
No ratings yet
D3E800A4763-Brake System
149 pages
Brake Systems
No ratings yet
Brake Systems
74 pages
Tiguan 2 2021 Brake System
No ratings yet
Tiguan 2 2021 Brake System
132 pages
Service: Scala 2019
No ratings yet
Service: Scala 2019
146 pages
SM 48.c
No ratings yet
SM 48.c
181 pages
A0051005420-Brake System
No ratings yet
A0051005420-Brake System
148 pages
D3E802F44BF Brake System
No ratings yet
D3E802F44BF Brake System
287 pages
VW Passat CC Brake Systems Eng
No ratings yet
VW Passat CC Brake Systems Eng
100 pages
D3E803BC25F-Brake System
No ratings yet
D3E803BC25F-Brake System
113 pages
Audi A8 2003 Brake
No ratings yet
Audi A8 2003 Brake
148 pages
VW Sharan 2011 Brake System Eng PDF
No ratings yet
VW Sharan 2011 Brake System Eng PDF
135 pages
VW t6 Brake Systems Eng
No ratings yet
VW t6 Brake Systems Eng
104 pages
D4B80A22C2D Brake System
No ratings yet
D4B80A22C2D Brake System
222 pages
VW Touareg 2 Brake System Eng
No ratings yet
VW Touareg 2 Brake System Eng
111 pages
Audi A4 2015 Brake System Eng
No ratings yet
Audi A4 2015 Brake System Eng
189 pages
Audi 100 Brake System Eng
No ratings yet
Audi 100 Brake System Eng
156 pages
Workshop Manual Transporter 2016 10-29
No ratings yet
Workshop Manual Transporter 2016 10-29
109 pages
SM 48
No ratings yet
SM 48
155 pages
Audi A8 2003 Brake System Workshop Manual Edition 032013
No ratings yet
Audi A8 2003 Brake System Workshop Manual Edition 032013
148 pages
Volkswagen Passat CC 2009, CC 2010, CC 2012 Workshop Manual - Brake System
50% (2)
Volkswagen Passat CC 2009, CC 2010, CC 2012 Workshop Manual - Brake System
100 pages
VW Passat Brake Systems
100% (6)
VW Passat Brake Systems
100 pages
SM 15
No ratings yet
SM 15
377 pages
SM 33.c
No ratings yet
SM 33.c
127 pages
q7 - 2007 - Repair Manual Brake System - 184
No ratings yet
q7 - 2007 - Repair Manual Brake System - 184
184 pages
Justinian S Flea Plague Empire and The Birth of Europe 1st Edition William Rosen Download
100% (2)
Justinian S Flea Plague Empire and The Birth of Europe 1st Edition William Rosen Download
44 pages
Nursing Students and Clinical Teachers Perceptions of Effective
100% (1)
Nursing Students and Clinical Teachers Perceptions of Effective
131 pages
2024 LS G7 NMP Week1 Day1
No ratings yet
2024 LS G7 NMP Week1 Day1
22 pages
The King Arthur Baking School Unknown Download
No ratings yet
The King Arthur Baking School Unknown Download
22 pages
ATOMixia PDF
No ratings yet
ATOMixia PDF
8 pages
SHS LCS Q1 Learning-Activity-Sheet
No ratings yet
SHS LCS Q1 Learning-Activity-Sheet
7 pages
Rekhaganitam in Sanskrit
100% (1)
Rekhaganitam in Sanskrit
683 pages
Instant Access To Graber and Wilbur's Family Medicine Examination and Board Review 5th Edition Edition Jason K. Wilbur Ebook Full Chapters
100% (3)
Instant Access To Graber and Wilbur's Family Medicine Examination and Board Review 5th Edition Edition Jason K. Wilbur Ebook Full Chapters
16 pages
Escobar Arturo Cultures Practices and Social Movement
No ratings yet
Escobar Arturo Cultures Practices and Social Movement
40 pages
Enerlites v. Century Prods. - Complaint
No ratings yet
Enerlites v. Century Prods. - Complaint
39 pages
The Art of Planning A Lesson
No ratings yet
The Art of Planning A Lesson
29 pages
When Core Values Are Strategic How The Basic Values of Procter Gamble Transformed Leadership at Fortune 500 Companies 1st Edition Rick Tocquigny Instant Download
100% (1)
When Core Values Are Strategic How The Basic Values of Procter Gamble Transformed Leadership at Fortune 500 Companies 1st Edition Rick Tocquigny Instant Download
35 pages
Discovering Public Domain Books
No ratings yet
Discovering Public Domain Books
395 pages
ProgrammingGuide Pass-1.2.2
No ratings yet
ProgrammingGuide Pass-1.2.2
22 pages
Assignment 1: Information Technology Ethics Issues (IT)
No ratings yet
Assignment 1: Information Technology Ethics Issues (IT)
4 pages
IRR of Local Government Code of 1991, As Amended
100% (5)
IRR of Local Government Code of 1991, As Amended
359 pages
GCRC5633 Iss 2-Recommendations For The Risk Assessment of Buffer Stops, Arresting Devices and End Impact Walls
No ratings yet
GCRC5633 Iss 2-Recommendations For The Risk Assessment of Buffer Stops, Arresting Devices and End Impact Walls
21 pages
Microalgal Biotechnology: Bioprospecting Microalgae For Functional Metabolites Towards Commercial and Sustainable Applications 1st Edition Jeyabalan Sangeetha Download
No ratings yet
Microalgal Biotechnology: Bioprospecting Microalgae For Functional Metabolites Towards Commercial and Sustainable Applications 1st Edition Jeyabalan Sangeetha Download
49 pages
DPP 4 6 0 W Im en PDF
No ratings yet
DPP 4 6 0 W Im en PDF
143 pages
Legal Guide To Social Media: Rights and Risks For Businesses, Entrepreneurs, and Influencers (2nd Edition) Kimberly A. Houser PDF Download
No ratings yet
Legal Guide To Social Media: Rights and Risks For Businesses, Entrepreneurs, and Influencers (2nd Edition) Kimberly A. Houser PDF Download
39 pages
Operating Manual Audiometry Module
No ratings yet
Operating Manual Audiometry Module
30 pages
Cambridge History of China Vol. 1 The Ch'in and Han Empires 221 BC AD 220 The Instant Download
100% (5)
Cambridge History of China Vol. 1 The Ch'in and Han Empires 221 BC AD 220 The Instant Download
23 pages
Holliday (1994)
No ratings yet
Holliday (1994)
13 pages
213 - Procedure - 0-Project Multi-Office Engineering Execution Plan
No ratings yet
213 - Procedure - 0-Project Multi-Office Engineering Execution Plan
9 pages
Industry Report Gaarlandt2025 AI Agents Are Changing How People Shop Here S What That Means For Brands
No ratings yet
Industry Report Gaarlandt2025 AI Agents Are Changing How People Shop Here S What That Means For Brands
10 pages
Intellectual Property Law P Narayanan 3rd Parameswaran Narayanan PDF Download
0% (1)
Intellectual Property Law P Narayanan 3rd Parameswaran Narayanan PDF Download
77 pages
Shaykh Nawawi of Banten Texts
No ratings yet
Shaykh Nawawi of Banten Texts
451 pages
The Love Contract Steph Vizard PDF Download
No ratings yet
The Love Contract Steph Vizard PDF Download
33 pages
Chapter 13: Power and Politics
No ratings yet
Chapter 13: Power and Politics
23 pages
PG 72292
No ratings yet
PG 72292
17 pages