Service

Workshop Manual
Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems
Edition 05.99

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.

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
45 - Anti-locking brake system
46 - Brakes, Brake mechanics
47 - Brakes, Brake hydraulics

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.

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 S01DAXX8920

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

45 - Anti-locking brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1 Anti-locking brake system (ABS) ITT Mark 20 IE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.1 General information on this ABS, ABS/EDL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Distinguishing features of ABS ITT Mark 20 IE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Notes for repair work on ABS, ABS/EDL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Electrical/electronic components and fitting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Faults displayed by warning lamps K14 , K47 and K118 . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Assembly overview - hydraulic unit, brake servo/ brake master cylinder (left-hand drive)
........................................................................ 11
4 Assembly overview - Hydraulic unit, right-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.1 Removing and installing control unit and hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5 Removing and installing parts of ABS system on front and rear axle . . . . . . . . . . . . . . . . 17
5.1 Removing and installing parts of ABS system on front axle, VW ll brake caliper . . . . . . . . 17
5.2 Removing and installing parts of ABS system on front axle, Lucas brake caliper . . . . . . . . 20
5.3 Removing and installing parts of ABS system on rear axle (vehicles with drum brakes) . . 24

46 - Brakes, Brake mechanics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1 Servicing front brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.1 Servicing front brakes, VW II caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2 Removing and installing brake pads/brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.3 Servicing front wheel brakes, Lucas brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.4 Removing and installing brake pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.5 Servicing front wheel brakes, Cupra -R- brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.6 Brake clips: removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.7 Brake pads: removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2 Servicing rear wheel brakes (drum brakes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
37
2.1 respectRemoving and
to the correctness installing
of information rear
in this wheelCopyright
document. brakes by SEAT. . S.A.
.................................. 37
2.2 Releasing brake shoe adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.3 Servicing rear brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.4 Removing and installing brake shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.5 Adjusting handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3 Removing and installing handbrake cable (drum brakes) . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.1 Removing and installing handbrake cable (drum brakes) . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4 Handbrake lever - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5 Brake pedal - Assembly overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.1 Separating brake pedal from brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.2 Removing and installing brake pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.3 Adjusting brake light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

47 - Brakes, Brake hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

1 Servicing VW II front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.1 Removing and installing front brake caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2 Servicing Lucas front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.1 Removing and installing front caliper piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
3 Servicing Cupra -R- front brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.1 Piston for front brake clip: removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4 Assembly overview: Brake pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Contents i
 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

5 Checking and adjusting brake pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

5.1 Load dependent brake pressure regulator specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6 Bleeding braking system on vehicles with and without ABS . . . . . . . . . . . . . . . . . . . . . . . . 63
6.1 Bleeding brakes with Brake filling and bleeder unit SAT 1150 . . . . . . . . . . . . . . . . . . . . . . 63
6.2 Bleeding brake system without brake filling and bleeding appliance . . . . . . . . . . . . . . . . . . 64
7 Assembly overview: brake master cylinder/brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.1 Removing and installing vacuum pump for brake servo (Diesel vehicles) . . . . . . . . . . . . . . 66
8 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
8.1 Removing and installing brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
9.1 Removing and installing brake servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

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.

ii Contents
 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

00 – Technical data
1 Technical data

1.1 Brakes
Model Ibiza, Córdoba
Engine/capacity l 1.0 1.4 1.9 SDI 1.6
Output kW 37 44 47 55
Brake master cylin‐ mm 20.64 / 22.2 1)
20.64 / 22.2 1)
20.64 / 22.21) 20.64 / 22.21)
der
Brake servo ∅ 8′′ / 9′′1) 8′′ / 9′′1) 9′′ 8′′ / 9′′1)
Front brake disc mm ∅ 239 239 239 239
Brake disc, thick‐ mm 20 20 20 20
ness
Brake disc, wear mm 18 18 18 18
limit
Brake drum mm ∅ 200 200 200 200
Brake drum, wear mm ∅ 201.5 201.5 201.5 201.5
limit
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Brake wheel cylin‐ permitted
mm ∅ 17.46
unless authorised by SEAT S.A. SEAT S.A does 17.46 17.46
not guarantee or accept any liability with 17.46
der respect to the correctness of information in this document. Copyright by SEAT S.A.

Brake lining, thick‐ mm 40 40 40 40

ness

1) Vehicles with ABS

Model Ibiza, Córdoba

Engine/capacity l 1.4 16V 1.9 TDI 1.4 16V 1.64) 1.6
Output kW 55 66 74 74 74
Brake master cylin‐ mm 20.64 / 22.2 22.2 / 23.81 22.2 / 23.81 22.2 / 23.81 22.2 / 23.812)
2) 2) 2) 2)

der
Brake servo ∅ 8′′ / 9′′2) 9′′ 9′′ 9′′ 9′′
Front brake disc mm ∅ 239 256 256 256 256
Brake disc, thick‐ mm 20 20 20 20 20
ness
Brake disc, wear mm 18 18 18 18 18
limit
Brake drum mm ∅ 200 200 200 200 200
Brake drum, wear mm ∅ 201.5 201.5 201.5 201.5 201.5
limit
Brake wheel cylin‐ mm ∅ 17.46 17.46 / 19.05 19.05 17.46 / 19.05 19.05
der 3) 3)

Brake lining, thick‐ mm 40 40 40 40 40

ness

2) Vehicles with ABS or ABS-EDL

3) Córdoba
4) Vehicles with automatic gearbox

1. Technical data 1
 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

Model Ibiza, Córdoba

Engine/capacity l 1.9 TDI 1.8 T
Output kW 81 110
Brake master cylin‐ mm 22.2 / 23.815) 23.81
der
Brake servo ∅ 9′′ 9′′
Front brake disc mm ∅ 280 280
Front brake disc, mm 22 22
thickness
Front brake disc, mm 20 20
wear limit
Rear brake disc mm ∅ 232 232
Rear brake disc, mm 9 9
thickness
Rear brake disc, mm 7 7
wear limit

5) Vehicles with ABS or ABS-EDL

Model Córdoba Vario

Engine/capacity l 1.4 1.9 SDI 1.6
Output kW 44 47 55
Brake master cylin‐ mm 20.64 / 22.26) 20.64 / 22.26) 20.64 / 22.26)
der
Brake servo ∅ 8′′ / 9′′6) 9′′ 8′′ / 9′′6)
Front brake disc mm ∅ 239 239 239
Brake disc, thick‐ mm 20 20 20
ness
Brake disc, wear mm 18 18 18
limit
Brake drum mm ∅ 200 200 200
Brake drum, wear mm ∅ 201.5 201.5 201.5
limit
Brake wheel cylin‐ mm ∅ 17.46 17.46 17.46
der
Brake lining, thick‐ mm 40 40 40
ness

6) Vehicles with ABS

7) Córdoba

Model Córdoba Vario

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Engine/capacity l 1.4 16V
permitted 1.9 S.A
unless authorised by SEAT S.A. SEAT TDIdoes not guarantee or accept any liability
1.6 with
respect to the correctness of information in this document. Copyright by SEAT S.A.
Output kW 55 66 74
Brake master cylin‐ mm 20.64 / 22.28) 22.2 / 23.818) 22.2 / 23.818)
der
Brake servo ∅ 8′′ / 9′′8) 9′′ 9′′
Front brake disc mm ∅ 239 256 256
Brake disc, thick‐ mm 20 20 20
ness
Brake disc, wear mm 18 18 18
limit

2 Rep. Gr. 00 - Technical data

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

Model Córdoba Vario

Brake drum mm ∅ 200 200 200
Brake drum, wear mm ∅ 201.5 201.5 201.5
limit
Brake wheel cylin‐ mm ∅ 17.46 19.05 19.05
der
Brake lining, thick‐ mm 40 40 40
ness

8) Vehicles with ABS or ABS-EDL

Model Córdoba Vario

Engine/capacity l 1.9 TDI
Output kW 81
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
Brake master cylin‐ mm respect to the correctness of information in this document. 22.2 / 23.81
Copyright by SEAT9)S.A.
der
Brake servo ∅ 9′′
Front brake disc mm ∅ 280
Front brake disc, mm 22
thickness
Front brake disc, mm 20
wear limit
Rear brake disc mm ∅ 232
Rear brake disc, mm 9
thickness
Rear brake disc, mm 7
wear limit

9) Vehicles with ABS or ABS-EDL

Vehicle with CUPRA -R- front brake clip

Model Ibiza Cupra -R-
Engine/capacity l 1.8
Power kW/HP 132/180
Master brake cylinder mm 23.81
Brake servo ∅ 9′′
Front brake disc mm ∅ 305
Front brake disc (thickness) mm 28
Front brake disc (wear limit) mm 26
Rear brake disc mm ∅ 232
Rear brake disc (thickness) mm 9
Rear brake disc (wear limit) mm 7

1. Technical data 3
 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

45 – Anti-locking brake system

1 Anti-locking brake system (ABS) ITT
Mark 20 IE

1.1 General information on this ABS, ABS/

EDL
Following variants are possible with ABS ITT Mark 20 IE:
♦ ABS
♦ ABS with electronic differential lock (ABS/EDL)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/EDL with traction control system (ABS/EDL/TCS)

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

ABS layout in left-hand drive vehicle.

The ABS brake system is divided diagonally. The servo-assis‐
tance is effected pneumatically, by the vacuum brake servo unit.
Vehicles with ITT Mark 20 IE ABS do not have a mechanical brake
pressure regulator. A specially matched software in the control
unit controls the rear axle brake pressure regulation.

The hydraulic unit -a- and control unit -b- form one component.
Separating is only possible when removed.
New control units via the replacement parts service are not coded
and require coding after installation.
Malfunctions on the ABS systems do not influence the brake sys‐
tem and servo. The conventional braking system remains func‐
tional even without ABS.

ABS layout in right-hand drive vehicle.

4 Rep. Gr. 45 - Anti-locking brake system

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

1.2 Distinguishing features of ABS ITT Mark

20 IE
I - ABS - ITT Mark 20 IE
Dimension a = 100 mm
II - ABS/EDL - ITT Mark 20 IE
Dimension a = 130 mm

ABS/EDL/TCS - ITT Mark 20 IE

Dimension a = 130 mm

1.3 Notes for repair work on ABS, ABS/EDL

♦ Before carrying out repair work on the anti-locking system,
determine the cause of the fault using self diagnosis ⇒ VAS
5051 .
♦ Before working on the ABS, ABS/EDL system, disconnect the
battery earth strap. On vehicles with coded radio, obtain cod‐
ing.
♦ Before carrying out welding work with an electric welding unit
⇒ General Notes; Body Repairs; General Body Repairs .
♦ When working with brake fluid, observe the valid, relevant
safety precautions and notes, ⇒ page 63 .
♦ Bleed brake system with Brake filling and bleeder unit -SAT
1150- after completing repairs where the brake system was
opened ⇒ page 63 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ During the final road test, ensure that aunless
permitted controlled brake
authorised by test
SEAT S.A. SEAT S.A does not guarantee or accept any liability with
is performed at least once (pulsationsrespect
musttobe felt at the brake
the correctness of information in this document. Copyright by SEAT S.A.

pedal).
♦ Absolute cleanliness is required when working on the anti-
locking brake system, it is not permitted to use any products
which contain mineral oils, such as oils, greases etc.

1. Anti-locking brake system (ABS) ITT Mark 20 IE 5

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

♦ Thoroughly clean all unions and the adjacent areas before

loosening, do not use aggressive cleaning agents such as
brake cleaner, petrol, thinners or similar.
♦ Place removed parts on a clean surface and cover.
♦ After separating the control unit/hydraulic unit use the trans‐
portation protection for the valve dome.
♦ Carefully cover or seal open components if repairs cannot be
carried out immediately.(Use sealing plugs repair kit -1H0 698
311 A- .
♦ Do not use fluffy cloths.
♦ Only remove replacement parts from packaging immediately
prior to installation.
♦ Only use genuine packed parts.
♦ When the system is open do not work with compressed air and
do not move the vehicle.
♦ Ensure that no brake fluid enters plug connectors.

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 Rep. Gr. 45 - Anti-locking brake system

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

2 Electrical/electronic components and fitting locations

1 - ABS hydraulic unit -N55-

The hydraulic unit consists of
the components:
❑ Hydraulic pump -V64- ,
checked by self-diagno‐
sis.
❑ Valve block (contains
the in/outlet valves).
❑ The hydraulic pump -
V64- and valve block
must not be separated
from one another
⇒ page 11
❑ When changing the hy‐
draulic unit always seal
the old part with the
plugs from the repair set
-1H0 698 311 A-
2 - ABS control unit -J104-
❑ Checked by self-diag‐
nosis
❑ Located on the hydraul‐
ic unit on left of engine
compartment.
❑ Checking the multi-pin
connector to control unit
⇒ VAS 5051
❑ Do not disconnect con‐
nector before success‐
fully completing inter‐
rogation of fault memo‐
ry. First switch ignition
off then separate con‐
nector.
3 - ABS/EDL hydraulic unit -
N55-
The hydraulic unit consists of the components:
❑ Hydraulic pump -V64- , checked by self-diagnosis.
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
❑ Valve block (contains the in/outlet valves).respect to the correctness of information in this document. Copyright by SEAT S.A.

❑ The hydraulic pump -V64- and valve block must not be separated from one another ⇒ page 11
❑ When changing the hydraulic unit, always seal the old part with the plugs from the repair set -1H0 698
311 A-
4 - ABS/EDL control unit -J104-
❑ Checked by self-diagnosis
❑ Located on the hydraulic unit on left of engine compartment.
❑ Checking the multi-pin connector to control unit ⇒ VAS 5051
❑ Do not disconnect connector before successfully completing interrogation of fault memory. First switch
ignition off then separate connector.
5 - Brake light switch -F-
❑ The brake light switch is open in the rest position.
❑ Adjusting ⇒ page 49
❑ Can be checked via read measured value block ⇒ VAS 5051

2. Electrical/electronic components and fitting locations 7

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

6 - Brake system warning lamp -K118-

❑ Location: In the dash panel insert
Function: ⇒ page 8

7 - ABS warning lamp -K47-

Locations:
❑ Location: in dash panel insert
Function: ⇒ page 8

8 - Handbrake warning lamp -K14-

❑ Location: In the dash panel insert
Function: ⇒ page 8
9 - Impulse wheel for rear right and left speed sensors
❑ Removing and installing ⇒ page 37
10 - Impulse wheel for front right and left speed sensors
❑ Removing and installing ⇒ page 28
11 - Front right/left speed sensor ( -G45- / -G47- )
❑ Checked by self-diagnosis
❑ Before inserting the sensor clean the inner surface of the sensor mounting and coat with lubricating paste
-G 000 650-
❑ When connecting the speed sensor wire ensure it is not twisted in the wheel housing
❑ Securing bolt tightening torque - 10 Nm
12 - Rear right/left speed sensor ( -G44- / -G46- )
❑ Installation instructions ⇒ Item 11 (page 8)
13 - Diagnostic connections
❑ Location: Behind driver's side stowage compartment

2.1 Faults displayed by warning lamps -

K14- , -K47- and -K118-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
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.
♦ If the ABS warning lamp -K47- -1- does not go out after switch‐
ing on the ignition and completion of the test sequence, the
fault may be:
a - voltage supply is below 10 Volt.
b - there is a fault in the ABS.
The anti-locking brake system remains switched off with an ABS
fault -b-, but the conventional brake system remains fully opera‐
tional.
c - since the last time the vehicle was started there was a tem‐
porary speed sensor fault.
In the case of sensor fault -c- the ABS warning lamp will extinguish
automatically after restarting the engine and 20 km/h (approx. 13
mph) is exceeded.
d - there is an open circuit in the connection from the dash panel
insert to control unit -J104- ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations
e - dash panel insert is defective.
Warning lamps -K47- and -K118-

8 Rep. Gr. 45 - Anti-locking brake system

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

♦ If the ABS warning lamp -K47- -1- , goes out, the brake system
warning lamp -K118- -2- remains on and 3 audible warning are
heard, the fault may be:
a - the brake fluid level is too low.
b - a fault in the activation of the brake system warning lamp -
K118- ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations
♦ If the ABS warning lamp -K47- -1- and the brake system warn‐
ing lamp -K118- -2- both come on, the ABS system is defective
and the EBD (electronic brake pressure distributor) is not func‐
tioning. A change in braking behaviour must be reckoned with.

Caution

When the ABS warning lamp -K47- and the brake system
warning lamp -K118- have lit up it is possible that the rear
wheels will lock up earlier when braking.

Warning lamp -K14-

♦ If the handbrake warning lamp -K14- -3- does not go out after
switching on the ignition, the fault may be:
a - the handbrake is pulled on.
b - the switch for the warning lamp -K14- is defective or incorrectly
set.
c - there is a wire routing fault. ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations
Vehicles with ABS/EDL
Problem: “EDL is not functioning on vehicle” .
For this problem a possible fault cause may be the brake light
switch is incorrectly adjusted ⇒ page 49 .
A further possibility is that the brake light switch is not functioning
⇒ VAS 5051 .

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.

2. Electrical/electronic components and fitting locations 9

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

2.1.1 Brake control system indicators for Ibi‐

za, Córdoba, Córdoba Vario 99 ▸
Position Identification
-1- Brake system control indicator -K118-
-2- ABS -K47- warning lamp
-3- TCS -K155- warning lamp
When connecting the ignition and/or starting the engine the sys‐
tem indicators -1- ABS -K47- , indicator -2- brake system -K118- ,
and indicator -3- antiskid program -K155- will light up for two sec‐
onds. Test sequence.
If after the test sequence is completed the indicators -K47- , -
K155- do not turn off, the fault causes can be:
♦ The voltage supply is less than 10 V
♦ There is a problem in the TCS system, or it has been discon‐
nected through the button -E256-
♦ There is a problem in the CAN-BUS line
♦ There is a problem in the ABS system
♦ The engine unit is coded incorrectly
♦ The ABS/EDL brake unit is coded incorrectly
♦ Checking brake fluid level

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

If after the test sequence is carried out, the ABS -K47- control
indicator and -K118- brake system indicator remain lit, the rear
wheels may be braking ahead of time.

Prior conditions to ensure good functioning of the ABS/EDL/TCS

brake system.
Depending on the motorisation test of the engine unit code.
– Diesel engines check if the engine unit code is correct ⇒ Rep.
Gr. 23 ; Preheating and direct injection system with distributor
pump
– Petrol engines check if the engine unit code is correct ⇒ Rep.
Gr. 24 ; Injection and starter system of the corresponding en‐
gine
♦ Consult the brake unit code ⇒ VAS 5051
♦ Consult the fault memory ⇒ VAS 5051
♦ Read measured value block ⇒ VAS 5051
♦ Comparison table ⇒ VAS 5051

10 Rep. Gr. 45 - Anti-locking brake system

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

3 Assembly overview - hydraulic unit, brake servo/ brake master cylinder

(left-hand drive)

Note!

Pump and valve block must not be separated from one another.

1 - Brake servo
2 - Tandem brake master cyl‐
inder
3 - Brake fluid reservoir
4 - Cap 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 - Self-locking nut, 25 Nm respect to the correctness of information in this document. Copyright by SEAT S.A.

6 - Torx socket head bolt T25,

4 Nm
7 - Torx socket head bolt T25,
8 Nm
8 - Rubber damper
9 - Retainer
10 - ABS hydraulic unit
11 - Control unit
12 - Brake pipe connection
❑ Hydraulic unit to front
right brake caliper
13 - Brake pipe connection
❑ Hydraulic unit to rear left
wheel cylinder
14 - Brake pipe connection
❑ Hydraulic unit to rear
right wheel cylinder
15 - Brake pipe connection
❑ Hydraulic unit to front
left brake caliper
16 - Brake pipe
❑ Master brake cylinder/
secondary piston circuit
to hydraulic unit
17 - Brake pipe
❑ Brake master cylinder/primary piston circuit to hydraulic unit

3. Assembly overview - hydraulic unit, brake servo/ brake master cylinder (left-hand drive) 11
 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

4 Assembly overview - Hydraulic unit, right-hand drive

Note!

Pump and valve block must not be separated from one another.

1 - Bracket
❑ Is secured to the mount‐
ing plate
2 - Self-locking nut, 10 Nm
❑ Always renew
3 - Rubber damper
4 - Self-locking nut, 25 Nm
❑ Always renew
5 - Stud, 8 Nm
6 - ABS hydraulic unit
7 - Brake pipe connection
❑ Hydraulic unit to front
left brake caliper
8 - Brake pipe connection
❑ Hydraulic unit to rear
right wheel cylinder
9 - Brake pipe connection
❑ Hydraulic unit to rear left
wheel cylinder
10 - Brake pipe connection
❑ Hydraulic unit to front
right brake caliper
11 - Control unit
12 - Heat shield
13 - Bolt, 8 Nm
14 - Clip
15 - Brake pipe connection
❑ Master brake cylinder/
secondary piston circuit to hydraulic unit
16 - Brake pipe connection
❑ Brake master cylinder/primary piston circuit to hydraulic unit

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.

12 Rep. Gr. 45 - Anti-locking brake system

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

Connecting brake pipes from tandem master cylinder to hydraulic

unit
Vehicles with ABS
A - Secondary piston circuit
B - Primary piston circuit
1 - Hydraulic unit to front right brake caliper
2 - Hydraulic unit to rear left wheel cylinder
3 - Hydraulic unit to rear right wheel cylinder
4 - Hydraulic unit to front left brake caliper

Vehicles with ABS/EDL

A - Secondary piston circuit
B - Primary piston circuit

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.

4. Assembly overview - Hydraulic unit, right-hand drive 13

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

4.1 Removing and installing control unit and

hydraulic unit
Special tools and work‐
shop equipment re‐
quired
♦ Torque wrench -SAT
8010-

Sealing plugs repair kit

After separating the con‐
trol unit from the hydraul‐
ic unit always fit the valve
dome transportation pro‐
tection on the hydraulic
unit. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Warranty claimsrespect
for hy‐
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.
draulic units on which the
valve dome transporta‐
tion protection was not
used, will not be accep‐
ted.
1- Valve dome trans‐
portation protec‐
tion (plastic foam)
2- Sealing plugs M 10
3- Sealing plugs M12
Location:
The control unit is bolted
to the hydraulic unit and
is located on left in the
engine compartment.

Caution

Do not bend the brake

pipes in the area of
the hydraulic unit!

4.1.1 Removing
– Obtain radio code on vehicles with coded radio.
– Disconnect battery.
– Remove coolant expansion tank and swing to side.
– Draw off as much brake fluid as possible from brake fluid res‐
ervoir using a suction bottle.

14 Rep. Gr. 45 - Anti-locking brake system

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

– Operate brake pedal and block or allow a second mechanic to

operate the pedal.
– Fit bleeder hose and bleeder bottle to the front left brake cal‐
iper bleeder screw and open bleeder screw.
– Close front left bleeder screw.
– Release control unit connector -arrow 1- and pull off
-arrow 2- .
– Place sufficient lint-free cloths under the control unit and hy‐
draulic unit.
Ensure no brake fluid gets onto contacts.
– Disconnect brake pipes on brake master cylinder and hydraul‐
ic unit and seal brake pipes and threaded holes with plugs from
repair kit -1H0 698 311 A- .
– Remove torx socket head bolt T25 from hydraulic unit bracket.
– Remove hydraulic unit with control
Protected unit.
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
Removing control unit from hydraulic unit
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Pull connector for hydraulic pump motor off control unit.

– Remove bolts from control unit and pull control unit off.

When pulling off control unit, ensure that the hydraulic unit valve
dome is not canted against the control unit solenoid valves.
Cover control unit magnetic coils with a lint-free cloth.
After separating control unit and hydraulic unit use transportation
protection for valve dome.

4.1.2 Installing

Note!

♦ Only remove sealing plugs on new hydraulic unit when the

corresponding brake pipe is going to be fitted.
♦ If the sealing plugs are removed too early, brake fluid can es‐
cape, it can then no longer be guaranteed that the unit is
sufficiently filled or adequately bled.

4. Assembly overview - Hydraulic unit, right-hand drive 15

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

When assembling control unit and hydraulic unit, ensure that the
hydraulic unit valve dome is not canted against the control unit
solenoid valves.
– Using new bolts, screw control unit to hydraulic unit. Observe
tightening torque max. 4 Nm.
– Fit connector on hydraulic pump motor.
– Bolt ABS unit to bracket.
Do not tighten bolts completely. Attaching the individual brake
pipes is made easier.
– After tightening brake pipes, tighten hydraulic unit.
– Further installation is carried out in the reverse sequence.
– Bleeding brake system ⇒ page 63 .
– Enter radio code.
– Code control unit ⇒ VAS 5051 .
Tightening torques:
For left-hand drive vehicles:
Control unit to hydraulic unit max. 4 Nm
Torx socket head bolts for hydraulic unit on bracket 8 Nm
Nut for tandem master brake cylinder to brake servo 25 Nm
Brake pipes to ABS unit:
Thread M 10 x 1 15 Nm
Thread M 12 x 1 15 Nm
For right-hand drive vehicles:
Control unit to hydraulic unit max. 4 Nm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Nut for hydraulic unit on bracket 10byNm
permitted unless authorised SEAT S.A. SEAT S.A does not guarantee or accept any liability with
Bracket on mounting plate 25 Nm
respect to the correctness of information in this document. Copyright by SEAT S.A.

Brake pipes to ABS unit:

Thread M 10 x 1 15 Nm
Thread M 12 x 1 15 Nm

16 Rep. Gr. 45 - Anti-locking brake system

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

5 Removing and installing parts of ABS

system on front and rear axle

5.1 Removing and installing parts of ABS system on front axle, VW ll brake
caliper

1 - Hexagon socket head bolt,

8 Nm
2 - ABS speed sensor
❑ Before inserting sensor,
clean fitting hole inner
surface and coat with lu‐
bricating paste -G 000
650-
3 - ABS speed sensor rotor
4 - Hub
❑ Pressing out and in ⇒
Running Gear, Axles,
Steering; Rep. Gr. 40 ;
Repair Group 40; Serv‐
icing front suspension
5 - Cross-head screw
6 - Brake disc, ventilated
❑ Ventilated brake disc: ∅
239,00 mm
❑ Brake disc thickness: 20
mm
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Wear limit: 16 mm 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 - Splash plate
8 - Wheel bearing housing

5.1.1 Removing and installing speed sensor

on front axle
Removing
– Raise vehicle.

5. Removing and installing parts of ABS system on front and rear axle 17
 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

– Separate speed sensor and speed sensor wiring connector

-1- .
– Remove bolt -2- from wheel bearing housing.
– Pull ABS speed sensor from wheel bearing housing.
Installing
– Before inserting speed sensor, clean hole inner surface and
coat speed sensor all-round with solid lubricant paste -G 000
650- .
– Insert speed sensor into wheel bearing housing hole and tight‐
en bolt to 10 Nm.
– Connect speed sensor to speed sensor wiring.

5.1.2 Checking or removing and installing ro‐

tor on front axle
– Raise vehicle.
– Check rotor -1- for damage by turning wheel.
– If the rotor is damaged, remove wheel hub with rotor and re‐
new rotor ⇒ Running Gear, Axles, Steering; Rep. Gr. 40 ;
Servicing front suspension .

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.

5.1.3 Removing and installing front speed

sensor wiring
Special tools and workshop equipment required
♦ Wiring harness repair set -VAS 1978-

Removing
– Obtain radio code on vehicles with coded radio.
– Disconnect battery.

18 Rep. Gr. 45 - Anti-locking brake system

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

– Release control unit connector -arrow 1- and pull off

-arrow 2- .

– Release secondary locking device (violet) in

-direction of arrow- with a screwdriver.

Contact assignment of connector -T25- wiring loom/ control unit

-J104-
Contact Connected to component ...
19 + 20 Front right speed sensor -G45-
1+2 Front left
Protected speed Copying
by copyright. sensorfor-G47-
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.

– Push out relevant contacts with an ejection tool from wiring

harness repair set -VAS 1978- .
– Separate connector from speed sensor wiring and speed sen‐
sor.
– Remove defective speed sensor wiring and guide in new
speed sensor wiring.
– Connect speed sensor to speed sensor wiring.

5. Removing and installing parts of ABS system on front and rear axle 19
 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

– Clip in speed sensor wiring -arrows- .

Ensure the wiring is not twisted when installing the speed sensor
wiring in the wheel housing.
– Guide contacts into connector housing.

– Push individual wiring seals in onto stop with an insertion tool

from -VAS 1978- .
– Secure contacts with secondary locking device and fit multi-
pin connector cover cap.

5.2 Removing and installing parts of ABS system on front axle, Lucas 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.

20 Rep. Gr. 45 - Anti-locking brake system

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

1 - Hexagon socket head bolt,

8 Nm
2 - ABS speed sensor
❑ Before inserting sensor,
clean fitting hole inner
surface and coat with lu‐
bricating paste -G 000
650-
3 - Wheel bearing housing
4 - Splash plate
5 - ABS speed sensor rotor
❑ Illustration shows rotor
in conjunction with
wheel hub Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
❑ Removing andpermitted
pressingunless 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.
in wheel hub ⇒ Running
Gear, Axles, Steering;
Rep. Gr. 40 ; Servicing
front suspension
6 - Brake disc, ventilated
❑ Dimensions and wear
limits ⇒ page 1
❑ When worn always re‐
new both sides.
❑ Never remove brake
discs from hub by force.
If necessary use pene‐
trating fluid, otherwise
brake discs can be dam‐
aged.

5.2.1 Removing and installing speed sensor

on front axle
Removing
– Raise vehicle.
– Separate speed sensor and speed sensor wiring connector
-1- .
– Remove bolt -2- from wheel bearing housing.
– Pull ABS speed sensor from wheel bearing housing.
Installing
– Before inserting speed sensor, clean hole inner surface and
coat speed sensor all-round with solid lubricant paste -G 000
650- .
– Insert speed sensor into wheel bearing housing hole and tight‐
en bolt to 10 Nm.
– Connect speed sensor to speed sensor wiring.

5. Removing and installing parts of ABS system on front and rear axle 21
 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

5.2.2 Checking or removing and installing ro‐

tor on front axle
– Raise vehicle.
– Check rotor -1- for damage by turning wheel.
– If rotor is damaged, remove wheel hub with rotor and renew
⇒ Running Gear, Axles, Steering; Rep. Gr. 40 ; Servicing front
suspension .

5.2.3 Removing and installing front speed

sensor wiring
Special tools and workshop equipment required
♦ Wiring harness repair set -VAS 1978-

Removing
– Obtain radio code on vehicles with coded radio.
– Disconnect battery.
– Release control unit connector -arrow 1- and pull off
-arrow 2- .

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.

22 Rep. Gr. 45 - Anti-locking brake system

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

– Release secondary locking device (violet) in

-direction of arrow- with a screwdriver.

Contact assignment of connector -T25- wiring loom/ control unit

-J104-
Contact Connected to component ...
19 + 20 Front right speed sensor -G45-
1+2 Front left speed sensor -G47-

– Push out relevant contacts with an ejection tool from wiring

harness repair set -VAS 1978- .
– Separate connector from speed sensor wiring and speed sen‐
sor.
– Remove defective speed sensor wiring and guide in new
speed sensor wiring.
– Connect speed sensor to speed sensor wiring.

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.

5. Removing and installing parts of ABS system on front and rear axle 23
 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

– Clip in speed sensor wiring -arrows- .

Ensure the wiring is not twisted when installing the speed sensor
wiring in the wheel housing.
– Guide contacts into connector housing.

– Push individual wiring seals in onto stop with an insertion tool

from -VAS 1978- .
– Secure contacts with secondary locking device and fit multi-
pin connector cover cap.

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.

5.3 Removing and installing parts of ABS system on rear axle (vehicles with
drum brakes)

24 Rep. Gr. 45 - Anti-locking brake system

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

1 - Hexagon socket head bolt,

8 Nm
2 - ABS speed sensor
❑ Before inserting sensor,
clean fitting hole inner
surface and coat with lu‐
bricating paste -G 000
650-
3 - Stub axle
4 - Back plate with brake shoes
❑ Release adjustment be‐
fore removing brake
drum ⇒ page 39
5 - ABS speed sensor rotor
❑ Checking or removing
and installing
⇒ page 26
6 - 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
respect to the correctness of information in this document. Copyright by SEAT S.A.

5.3.1 Removing and installing speed sensor

on rear axle
Removing
– Fold rear seat bench forwards.
– Separate speed sensor wiring connector -arrow- .
– Raise vehicle.

5. Removing and installing parts of ABS system on front and rear axle 25
 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

– Remove bolt -arrow- from speed sensor.

– Pull speed sensor out from stub axle and brake carrier.

– Unclip speed sensor wiring from retainer -1- .

– Unclip grommet -2- and pull speed sensor wiring out from ve‐
hicle interior.
Installing
– Before inserting speed sensor, clean hole inner surface and
coat speed sensor all-round with lubricant paste -G 000 650- .
– Installation is carried out in the reverse sequence.

5.3.2 Checking or removing and installing ro‐

tor on rear axle
Special tools and workshop equipment required
♦ Tool set -U-40450-

Removing
– Raise vehicle.
– Remove wheel.
– Releasing brakes.
– Insert a screwdriver through a hole in the brake drum and push
the wedge upwards.
– Remove brake drum.
– Remove wheel hub with wheel bearing
Protected ⇒ Running
by copyright. Gear,or commercial purposes, in part or in whole, is not
Copying for private
Axles, Steering; Rep. Gr. permitted
42 ; Servicing wheel
unless authorised bearings
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.
– Check rotor and renew if necessary.

26 Rep. Gr. 45 - Anti-locking brake system

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

– Lever rotor -1- off wheel hub -2- with a screwdriver.

Installing

– Press rotor -1- on to wheel hub -2- .

– Install wheel hub ⇒ Running Gear, Axles, Steering; Rep. Gr.
42 ; Servicing wheel bearings .
– Install brake drum.
– Firmly depress brake pedal once, this adjusts the rear brakes.

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.

5. Removing and installing parts of ABS system on front and rear axle 27
 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

46 – Brakes, Brake mechanics

1 Servicing front brakes

1.1 Servicing front brakes, VW II caliper

Note!

♦ After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake
pads are properly seated in the normal operating position.
♦ To draw off brake fluid from the reservoir, use a bleeder bottle which is used only for brake fluid. Brake fluid
is poisonous and must on no account be sucked out by mouth using a hose!
♦ Fit brake pedal depressor -V.A.G 1869/2- before removing a brake caliper or disconnecting a brake hose.
♦ Wheel bolts tightening torque: 110 Nm
♦ Do not re-use used brake fluid.

1 - 10 Nm
2 - ABS speed sensor
❑ Before inserting sensor,
clean fitting hole inner
surface and coat with lu‐
bricating paste -G 000
650-
3 - Speed sensor rotor
❑ Only on vehicles with
ABS
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

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

❑ Pressing out and in ⇒

Running Gear, Axles,
Steering; Rep. Gr. 40 ;
Servicing front suspen‐
sion
5 - Cross-head screw
6 - Brake disc, ventilated
❑ Dimensions and wear
limits ⇒ page 1
❑ When worn always re‐
new both sides.
❑ Never remove brake
discs from hub by force.
If necessary use pene‐
trating fluid, otherwise
brake discs can be dam‐
aged.

28 Rep. Gr. 46 - Brakes, Brake mechanics

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

7 - Cross-head screw
8 - Hexagon bolt, 10 Nm
9 - Splash plate
10 - Wheel bearing housing
11 - Brake pad
❑ With riveted retaining spring
❑ Checking thickness ⇒ Maintenance ; Booklet
❑ Always renew both sides
❑ Removing and installing ⇒ page 29
❑ Allocation ⇒ Replacement parts catalogue
12 - Lower hexagon socket head bolt, 25 Nm
13 - Upper hexagon socket head bolt, 25 Nm
14 - Lower spacer sleeve
15 - Upper spacer sleeve
16 - Lower bush
17 - Upper bush
18 - Lower sleeve
19 - Upper sleeve
20 - Brake caliper
❑ Repairing ⇒ page 29
❑ Removing and installing ⇒ page 29
21 - Brake hose

1.2 Removing and installing brake pads/

brake caliper
Special tools and workshop equipment required
♦ Torque wrench -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.

1. Servicing front brakes 29

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

♦ Piston resetting tool -T20055-

1.2.1 Removing
– After removing the hexagon socket head bolts swing caliper
out upwards.
– Take off brake caliper housing and secure with wire so that the
weight of the brake caliper does not stress or damage the
brakehose.
– Remove brake pads.
Use methylated spirit only for cleaning the brake caliper housing.

1.2.2 Installing

Note!

Before inserting new brake pads, press piston back into the cyl‐
inder with resetting tool. Before pressing the piston back, draw off
brake fluid from the reservoir with a bleeder bottle. Otherwise
particularly if reservoir has been topped up, fluid will overflow and
cause damage.
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
– Pressing piston back. respect to the correctness of information in this document. Copyright by SEAT S.A.

– Insert brake pads.

Brake pad with larger pad surface fitted to outer side!

30 Rep. Gr. 46 - Brakes, Brake mechanics

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

– Install brake caliper housing with brake pads to wheel bearing

housing.
– Fit brake caliper housing lower side -arrow- first.
The brake caliper housing pins must fit behind the wheel bearing
housing guide!
– Screw hexagon socket head bolt into brake caliper housing
andtighten to 25 Nm.

1.3 Servicing front wheel brakes, Lucas brake caliper

Note!

♦ After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake
pads are properly seated in their normal operating position.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ To draw off brake fluid from the reservoir, use
permitted a authorised
unless bleederbybottle which
SEAT S.A. is used
SEAT S.A does notonly for orbrake
guarantee fluid.
accept any Brake
liability with fluid
is poisonous and must on no account be sucked out
respect to the by mouth
correctness usinginathishose!
of information document. Copyright by SEAT S.A.

♦ Fit brake pedal depressor -V.A.G 1869/2- before removing a brake caliper or disconnecting a brake hose.
♦ Wheel bolts tightening torque: 110 Nm
♦ Do not re-use used brake fluid.

1. Servicing front brakes 31

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

1 - Brake disc, ventilated

❑ Dimensions and wear
limits ⇒ page 1
❑ When worn always re‐
new both sides.
❑ Never remove brake
discs from hub by force.
If necessary use pene‐
trating fluid, otherwise
brake discs can be dam‐
aged.
2 - Cross-head screw
3 - Brake pad
❑ Removing and installing
⇒ page 33
❑ Checking thickness
⇒ Maintenance ; Book‐
let
4 - Hub
❑ Pressing out and in ⇒
Running Gear, Axles,
Steering; Rep. Gr. 40 ;
Servicing front suspen‐
sion
5 - Hexagon bolt, 10 Nm
6 - Splash plate
7 - Wheel bearing housing
8 - Brake carrier with guide
pins and protective caps
❑ Supplied as replace‐
ment part assembled
with sufficient amount of
grease on guide pins
❑ If protective caps are damaged use repair kit
❑ Use grease sachet supplied to lubricate guide pins
9 - Heat shield
❑ Insert into piston
10 - Brake caliper
❑ Servicing ⇒ page 53
❑ Removing and installing ⇒ page 33
11 - Self-locking hexagon bolt, 35 Nm
❑ Renew
12 - Guide pin
13 - Ribbed combi-bolt, 125 Nm
14 - Protective Protected
cap 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
15 - Hexagon socket head
respect to thebolt, 8 Nm
correctness of information in this document. Copyright by SEAT S.A.

16 - ABS speed sensor

❑ Before inserting sensor, clean fitting hole inner surface and coat with lubricating paste -G 000 650-

32 Rep. Gr. 46 - Brakes, Brake mechanics

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

1.4 Removing and installing brake pads

Special tools and workshop equipment required
♦ Torque wrench -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
♦ Piston resetting tool -T20055- respect to the correctness of information in this document. Copyright by SEAT S.A.

1.4.1 Removing
– Remove lower brake caliper housing securing bolt. Counter
hold on guide pin.

– Swing brake caliper housing upwards.

– Remove brake pads.

1. Servicing front brakes 33

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

1.4.2 Installing

Note!

Before inserting new brake pads, press piston back into the cyl‐
inder with resetting tool. Before pressing the piston back, draw off
brake fluid from the reservoir with a bleeder bottle. Otherwise
particularly if reservoir has been topped up, fluid will overflow and
cause damage.

– Press piston back.

– Insert brake pads.
– Swing brake caliper housing down and tighten hexagon bolt
to 35 Nm.

Note!

♦ The repair kit includes four self-locking hexagon bolts which

must installed in all cases.
♦ After replacing the brake pads, depress pedal firmly several
times with the vehicle stationary so that the brake pads are
properly seated in their normal operating position.

1.5 Servicing front wheel brakes, Cupra -R- brake caliper

Note!

♦ After replacing the brake pads, step on the brake pedal a few times with the vehicle stopped, for the pads
to adapt to their working position.
♦ Use an extraction bottle, which should only come into contact with the brake fluid, to extract fluid from the
tank. Brake fluid is toxic and should never be sucked into the mouth through a flexible tube!
♦ Wheel bolt tightening torque: 110 Nm.
♦ Never reuse used brake fluid.

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.

34 Rep. Gr. 46 - Brakes, Brake mechanics

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

1 - Brake disc
❑ Dimensions and wear
limit ⇒ page 1
❑ In case of wear replace
the discs of the same
shaft.
❑ Do not use force to sep‐
arate the brake from the
wheel stock, use deoxi‐
dant if necessary, as
you could damage the
brake disc.
2 - Cupra -R- brake clip
3 - Brake clip securing bolt Tor‐
que 110 Nm
4 - Clip support
5 - Brake pads
❑ Removal and assembly
⇒ page 36
❑ Thickness 9 mm
6 - Brake pad securing bolt
7 - Compression spring
8 - Brake fluid hose 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
9 - Connection bolt support to respect to the correctness of information in this document. Copyright by SEAT S.A.
clip Tightening torque 95 Nm

1.6 Brake clips: removal and installation

– Loosen the brake fluid ring from its clip.
Tightening torque: 15 Nm
– Remove the two screws -arrow- for connecting the clip to the
housing of the bearing.
Tightening torque: 110 Nm
– Remove the brake clip from its coupling in the bearing housing.

1. Servicing front brakes 35

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

Remove the brake pads from the clip: on the work bench
– Remove the bolts -arrow- that join the pads to the brake clip
using a 4-mm punch in order to remove the pads.

Note!

♦ To facilitate the removal and installation of the securing bolts

press the pad-retainer spring lightly.
♦ After replacing the brake pads, step on the brake pedal a few
times with the vehicle stopped, for the pads to adapt to their
working position.

1.7 Brake pads: removal and installation

1.7.1 Removal
– Turn steering towards the clip.

Note!

To facilitate the removal and installation of the securing bolts

press pad-retainer spring -1- lightly.

– Remove the two -arrows- bolts that secure the pads to the
brake clip using a 4-mm-diameter punch.
– Remove the pads and the retainer spring -1- through the front
part of the brake clip.
Only alcohol may be used to clean the brake clip housing.

Note!

Before fitting the new brake pads retract the pistons in the cylin‐
der. Before retracting the pistons use an extraction bottle to
extract fluid from thebytank.
Protected Otherwise
copyright. if brake
Copying for private fluid has
or commercial been
purposes, re‐or in whole, is not
in part
placed it might leakunless
permitted andauthorised
causebydamage.
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.

1.7.2 Installation
– Install in reverse order.

36 Rep. Gr. 46 - Brakes, Brake mechanics

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

2 Servicing rear wheel brakes (drum

brakes)
Special tools and workshop equipment required
♦ Torque wrench -SAT 8010-

2.1 Removing and installing rear wheel brakes

Note!

♦ After replacing a wheel cylinder, a back plate and brake linings, depress brake pedal firmly several times
with vehicle stationary so that the brake linings are properly seated in their normal operating position.
♦ To draw off brake fluid from the reservoir, use a bleeder bottle which is used only for brake fluid. Brake fluid
is poisonous and must on no account be sucked out by mouth using a hose!
♦ Depress brake pedal and block before removing a brake wheel cylinder, a backing plate or disconnecting
a brake pipe.

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.

2. Servicing rear wheel brakes (drum brakes) 37

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

1 - Hexagon socket head bolt,

8 Nm
2 - ABS speed sensor
❑ Before inserting sensor,
clean fitting hole inner
surface and coat with lu‐
bricating paste -G 000
650-
3 - Stub axle
4 - Back plate with brake shoes
❑ Removing:
– Releasing brakes
⇒ page 39
– Remove brake drum

– Removing wheel hub

with wheel bearings ⇒
Running Gear, Axles,
Steering; Rep. Gr. 42 ;
Servicing wheel bear‐
ings

– Depress brake pedal

and block

– Unscrew brake pipe 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
⇒ Item 14 (page 39) respect to the correctness of information in this document. Copyright by SEAT S.A.

– Remove back plate

❑ Installing:
– Install back plate

– Fit brake pipe

⇒ Item 14 (page 39)

– Remove block from brake pedal

– Install wheel hub with wheel bearings ⇒ Running Gear, Axles, Steering; Rep. Gr. 42 ; Servicing wheel
bearings

– Install brake drum

– Bleed brake system ⇒ page 63

❑ Servicing ⇒ page 39
5 - Hexagon bolt, 60 Nm
6 - Brake drum
❑ Dimensions and wear limits ⇒ page 1
❑ Clean thoroughly, check for wear, damage, dimensions and for perfect braking surfaces
7 - Cross-head screw, 4 Nm
8 - Cap
❑ Pressing off and driving in ⇒ Running Gear, Axles, Steering; Rep. Gr. 42 ; Servicing wheel bearings
9 - Self-locking 12-point nut, 175 Nm
❑ Renew each time after removing
10 - Wheel hub with wheel bearing
❑ Only renew complete
❑ Removing and installing ⇒ Running Gear, Axles, Steering; Rep. Gr. 42 ; Servicing wheel bearings

38 Rep. Gr. 46 - Brakes, Brake mechanics

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

11 - ABS speed sensor rotor

12 - Handbrake cable
❑ Adjusting handbrake ⇒ page 42
13 - Axle beam
14 - Brake pipe

2.2 Releasing brake shoe adjustment

– Insert a screwdriver through a threaded hole in the brake drum
and push the wedge upwards.

2.3 Servicing rear brakes

Special tools and workshop equipment required
♦ Wedge -U-30800-

♦ Torque wrench -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.

2. Servicing rear wheel brakes (drum brakes) 39

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

Note!

♦ After working on the rear wheel brakes:

♦ Release handbrake.
♦ Firmly depress the brake pedal once.

1 - Spring plate
❑ To remove, push
against the spring and
turn through 90°
2 - Spring
3 - Brake shoe with lever for
handbrake
❑ Removing and installing
⇒ page 41
❑ Adjusting handbrake
⇒ page 42
4 - Upper return spring
❑ Unhook with pliers
5 - Lower return spring
❑ Lubricate contact points
with paste -G 000 650-
6 - Spring
7 - Brake shoe
❑ Removing and installing
⇒ page 41
❑ Minimum lining thick‐
ness 2.5 mm
❑ Checking thickness Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

⇒ Maintenance ; Book‐
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.
let
8 - Sealing cap
❑ Remove to check brake
lining thickness
9 - Pin
10 - Back plate
11 - Hexagon socket head bolt,
10 Nm
12 - Wheel cylinder
❑ Checking for leaks ⇒ page 41
13 - Wedge
❑ To remove and install the brake drum, push wedge upwards (tool through a wheel bolt hole)
⇒ page 39
14 - Push rod
❑ Lubricate contact points with paste -G 000 650-
15 - Locating spring
❑ Unhook with pliers

40 Rep. Gr. 46 - Brakes, Brake mechanics

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

Checking wheel cylinder for leaks

– Lift dust boot.
– If brake fluid is found in the dust boot then renew wheel cylin‐
der.
Care is to be exercised to ensure the dust boot is not damaged
when lifting.

2.4 Removing and installing brake shoes

2.4.1 Removing
– Remove brake drum ⇒ page 37 , Removing and installing rear
wheel brakes.
– Remove spring plate.
– Lever out brake shoe in -direction of arrow- with aid of a screw‐
driver behind support plate.
– Place brake shoe down on lower support plate.
– Unhook lower return spring.
– Unhook handbrake cable.
– Remove brake shoes.
– Clamp brake shoes in vice.

– Remove wedge spring.

– Remove upper return spring.

– Unhook locating spring.

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.

2. Servicing rear wheel brakes (drum brakes) 41

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

2.4.2 Installing
– Connect locating spring and fit brake shoes on the push rod.
– Insert wedge.

– Insert brake shoe with brake lever in push rod.

– Connect upper return spring.
– Connect handbrake cable to brake lever.
– Place brake shoes on wheel cylinder pistons.
– Connect lower return spring and lift brake shoes onto lower
support.
– Attach spring for wedge.
– Fit springs and spring plates.
– Install brake drum.
– Firmly depress brake pedal once.
– Adjust handbrake ⇒ page 42 .

2.5 Adjusting handbrake

Note!

A new adjustment is only necessary when the handbrake cable,

back plate or brake pads/linings are renewed.

– Release handbrake.
– Remove handbrake lever trim ⇒ General body repairs, Inte‐
rior; Rep. Gr. 68 ; Compartments, covers and trims; Removing
hand grip and trim for handbrake .
– Firmly depress brake pedal once.
– Pull handbrake lever on four notches.
– Tighten adjusting nuts -arrows- until both wheels are difficult
to turn by hand.
– Release handbrake and check that both wheels turn freely. If
required turn adjusting nut(s) back slightly.

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.

Due to the automatic rear wheel brake adjustment there is no re‐

quirement to adjust the handbrake after making new/initial ad‐
justment.

42 Rep. Gr. 46 - Brakes, Brake mechanics

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

2.5.1 Checking handbrake

– Raise vehicle.
– Pull handbrake lever on four notches.
– Wheels must not be able to be turned by hand.
– Release handbrake and check that both wheels turn freely.

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.

2. Servicing rear wheel brakes (drum brakes) 43

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

3 Removing and installing handbrake

cable (drum brakes)

3.1 Removing and installing handbrake ca‐

ble (drum brakes)

3.1.1 Removing
– Remove handbrake lever trim ⇒ General Body Repairs, Inte‐
rior; Rep. Gr. 68 ; Compartments, covers and trims; Removing
hand grip and trim for handbrake .
– Release handbrake.
– Loosen relevant adjustment nut -arrows- until the handbrake
cable can be unhooked from the compensator.
– Raise vehicle.
– Remove wheel.
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 drum.
respect to the correctness of information in this document. Copyright by SEAT S.A.

– Unhook handbrake cable.

– Unclip handbrake cable from retainer on rear axle -arrow A-

and unhook from retainer -arrow- .

– Unhook handbrake cable from retainer -arrow- .

– Pull handbrake cable out of guide tube -1- in
-direction of arrow- .

44 Rep. Gr. 46 - Brakes, Brake mechanics

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

3.1.2 Installing
– Slide handbrake cable into guide tube -1- in
-direction of arrow- .
– Hook handbrake cable into retainer -arrow- .
– Connect handbrake cable to brake lever.
– Install brake drum.

– Clip handbrake cable into retainer on rear axle -arrow A- .

– Handbrake cable clamping ring must lie in the middle of the
clip.
– Hook handbrake cable into retainer -arrow- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Hook handbrake cable
permitted unless into by
authorised compensator.
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.

– Tension handbrake cable with relevant adjustment nut

-arrows- .
– Adjusting handbrake ⇒ page 42 .
– Install handbrake lever trim ⇒ General Body Repairs, Interior;
Rep. Gr. 68 ; Compartments, covers and trims; Removing
hand grip and trim for handbrake .

3. Removing and installing handbrake cable (drum brakes) 45

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

4 Handbrake lever - Assembly overview

1 - Handbrake lever
2 - Hand grip
❑ Pull off forwards having
first pressed locking lug
down with a small
screwdriver
3 - Hexagon nut, 25 Nm
4 - Compensator
5 - Handbrake cable
❑ Removing and installing
(drum brakes)
⇒ page 44
6 - Adjusting nut
❑ Adjusting handbrake:
– Vehicles with drum
brakes ⇒ page 42

7 - Lock nut
❑ Lock on adjusting nut

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.

46 Rep. Gr. 46 - Brakes, Brake mechanics

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

5 Brake pedal - Assembly overview

Caution

The brake pedal travel must not be restricted by additional floor

coverings.

Note!

Grease all mountings before installing with grease -G 000 602- .

1 - Mounting bracket
2 - Hexagon bolt, 25 Nm
3 - Brake pedal switch -F47-
❑ For engine control unit
❑ Checking or adjusting ⇒
Rep. Gr. 24 ; Checking
additional signals
4 - Self-locking hexagon nut,
25 Nm
❑ Qty. 5, to secure mount‐
ing bracket to brake ser‐
vo
5 - Brake light switch
❑ Removing and installing
❑ Before installing brake
light switch, connect
brake pedal to brake
servo push rod
6 - Securing clip
❑ Ensure seated securely
7 - Pivot pin for brake and
clutch pedals
❑ Installation position:
The groove -arrow- is lo‐
cated on the clutch ped‐
al side.
8 - Brake pedal
9 - Mounting bush
❑ To support casing
10 - Pad
11 - Clutch pedal
❑ Removing and installing ⇒ Rep. Gr. 30 ; Clutch
12 - Securing clip Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not

❑ Ensure seated securely

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.

13 - Hexagon nut, 25 Nm
14 - Support

5. Brake pedal - Assembly overview 47

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

5.1 Separating brake pedal from brake ser‐

vo
Special tools and workshop equipment required
♦ Device to disconnect brake pedal piston -U-40015-

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.
– Remove driver's side covering.
– Remove brake light switch.
– Remove brake pedal switch -F47- .
– First press brake pedal in direction of brake servo and hold.
1- Brake pedal
2- Push rod
3- Retaining lugs
– Fit device -U-40015- and pull towards drivers seat, when doing
this counter-hold on brake pedal (pedal must not be able to
move to rear at this moment). This will press the retainers
-3- of the mounting off the ball head of the push rod -2- .

Note!

For ease of illustration separating the brake pedal from the brake
servo is shown with the pedal cluster removed.

– Pull device -U-40015- and brake pedal together towards driv‐

ers seat. (The brake pedal will then be pulled off the ball head
of the push rod).

5.1.1 Joining brake pedal to brake servo

– Hold push rod ball head in front of mounting and push brake
pedal in direction of brake servo, so that the ball head audibly
locates.
Further installation is performed in reverse order.
– Adjust brake light switch ⇒ page 49 .
– Install brake pedal switch -F47- and adjust ⇒ Rep. Gr. 24 ;
Checking additional signals .

48 Rep. Gr. 46 - Brakes, Brake mechanics

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

5.2 Removing and installing brake pedal

Note!

Grease all bearing and contact surfaces with grease -MoS2- .

5.2.1 Removing
– Remove driver's side stowage compartment.
– Remove brake light switch.
– Remove brake pedal switch -F47- .
– Separate brake pedal from brake servo ⇒ page 48 .
– Take brake pedal side pivot pin securing clip off towards switch
panel -direction of arrow- by locating a screwdriver under the
retaining clip -A- .
– Pull clutch and brake pedal pivot pin out to the left, until the
brake pedal can be removed.
– Remove brake pedal.

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.

5.2.2 Installing
Install in reverse order.
– Install brake light switch and adjust ⇒ page 49 .
– Install brake pedal switch -F47- and adjust ⇒ Rep. Gr. 24 ;
Checking additional signals .

5.3 Adjusting brake light switch

Note!

Remove brake light switch to adjust.

– Remove driver's side stowage compartment.

– Remove brake light switch -1- by turning 45° to left.
– Brake pedal in rest position.
– Guide brake light switch -1- through assembly opening until a
gap of 2.5 mm exists between the switch housing and the
brake pedal, and install again by turning 45° to the right.
– Operate brake pedal.
• Both brake lights must light up.
– Take foot off brake pedal.
• Both brake lights must not light up.

5. Brake pedal - Assembly overview 49

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

47 – Brakes, Brake hydraulics

1 Servicing VW II front brake caliper

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 thin coat of fitting paste -G 052 150 A2- to brake cylinders, pistons and seals.

1 - Protective seal
❑ Do not damage when in‐
serting piston
2 - Piston
❑ Removing and installing
⇒ page 50
❑ First apply a thin coat of
fitting paste -
G 052 150 A2- .
3 - Brake caliper housing
4 - Seal
❑ Removing and installing
⇒ page 50

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.

1.1 Removing and installing front brake cal‐

iper piston
Special tools and workshop equipment required

50 Rep. Gr. 47 - Brakes, Brake hydraulics

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

♦ Wedge -U-30800-

♦ Piston resetting tool -T20055-

1.1.1 Removing
– Force piston out of brake caliper housing using compressed
air.

Note!

Place a piece of wood in the recess to prevent damaging the pis‐

ton.
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.

– Take seal out using wedge -U-30800- .

Note!

When removing ensure that the surface of the cylinder is not

damaged.

1.1.2 Installing
– Clean the piston surfaces and seal only with white spirits and
then dry.
– Apply a thin coat of fitting paste -G 052 150 A2- to piston and
seal before installing.

1. Servicing VW II front brake caliper 51

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

– Place protective seal outer sealing lip on the piston.

– Insert inner sealing lip into groove in cylinder using wedge -

U-30800- .

Note!

When doing this hold piston in front of caliper 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
respect to the correctness of information in this document. Copyright by SEAT S.A.
– Press piston into brake caliper housing with piston resetting
tool -T20055- .

Note!

The protective seal outer sealing lip will then locate in the piston
groove.

52 Rep. Gr. 47 - Brakes, Brake hydraulics

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

2 Servicing Lucas front brake caliper

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 thin coat of fitting paste -G 052 150 A2- to brake cylin‐
ders, pistons and seals.

1 - Protective seal
2 - Bleed valve
❑ Apply a thin coat of fit‐
ting paste -G 052 152
A2- to the threads be‐
fore screwing in
3 - Brake caliper housing
4 - Self-locking
Protected hexagon
by copyright. Copying for private bolt,
or commercial purposes, in part or in whole, is not
35unless
permitted Nmauthorised 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.
❑ Renew
❑ When loosening and
tightening counter-hold
on guide pin
5 - Seal
❑ Take out using wedge -
U-30800- ⇒ page 53
6 - Piston
❑ Removing and installing
⇒ page 53
❑ First apply a thin coat of
fitting paste -
G 052 150 A2- .
7 - Protective seal
❑ Do not damage when in‐
serting piston
8 - Brake carrier with guide
pins and protective caps
❑ Brake carrier with guide
pins and protective cap
❑ Supplied as replace‐
ment part assembled
with sufficient grease on
guide pins
❑ If protective caps or guide pins are damaged use repair kit. Use grease sachet supplied to lubricate guide
pins.

2.1 Removing and installing front caliper

piston
Special tools and workshop equipment required

2. Servicing Lucas front brake caliper 53

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

♦ Wedge -U-30800-

♦ Piston resetting tool -T20055-

2.1.1 Removing
– Force piston out of brake caliper housing using compressed
air.

Note!

Place a piece of wood in the recess to prevent damaging the pis‐

ton.
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.

– Take seal out using wedge -U-30800- .

Note!

When removing ensure that the surface of the cylinder is not

damaged.

2.1.2 Installing
– Clean the piston surfaces and seal only with white spirits and
then dry.
– Apply a thin coat of fitting paste -G 052 150 A2- to piston and
seal before installing.

54 Rep. Gr. 47 - Brakes, Brake hydraulics

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– Place protective seal with the outer sealing lip on the piston.

– Using wedge -U-30800- , insert the inner sealing lip into the
grove in the cylinder.

Note!

When doing this hold piston in front of caliper housing.

– Press piston into the brake caliper housing using piston reset‐
ting tool.

Note!

The protective seal outer sealing lip will then locate in the piston
groove.

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.

2. Servicing Lucas front brake caliper 55

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3 Servicing Cupra -R- front brake caliper

Note!

♦ If repairing the clip unit, install the whole repair unit.

♦ Apply a thin layer of -G052 154 A2- paste to the brake cylinders, pistons and protector rings.

1 - Protection covers
❑ Avoid damaging them
on fitting them to the pis‐
ton.
2 - Pistons
❑ Removal and installa‐
tion ⇒ page 56
❑ Oil the piston first with a
thin layer of -G052 154
A2- paste.
3 - Housing for brake clip
4 - O-ring gasket rings
❑ Removal and installa‐
tion ⇒ page 56

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.

3.1 Piston for front brake clip: removal and

installation
Special tools and workshop equipment required

56 Rep. Gr. 47 - Brakes, Brake hydraulics

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

♦ Installation wedge -U-30800-

♦ Device for retracting piston -T20121-

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

3.1.1 Removal 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 tool -T20121- to the brake clip -arrow- to make sure the
pistons that are not to be removed do not move.
– Release the piston from the brake clip applying compressed
air.
– Extract the gasket ring with the -U-30800- installation wedge.

Note!

♦ Make sure the cylinder surface does not get damaged during
disassembly.
♦ Do not change the position of the pistons, they are to be fitted
to their cylinder.

3.1.2 Installation
– Clean the surfaces of the piston and ring gaskets with alcohol
only and then dry.
– Cover the surface of the piston and ring gasket with a thin layer
of -G 052 152 A2- paste before fitting them.
– Insert the sealing O-gasket inside the groove of the cylinder
using wedge -U-30800- .
– Fit the outside sealing protective cover over the piston.
– Carefully fit the piston to its corresponding cylinder in the brake
clip housing.
– Tighten the brake piston with tool -T20121- to attach it to its
cylinder.

3. Servicing Cupra -R- front brake caliper 57

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

– In the course of this operation the outside seal falls into the
slot in the brake clip.

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.

58 Rep. Gr. 47 - Brakes, Brake hydraulics

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

4 Assembly overview: Brake pressure regulator

1 - Brake pressure regulator

❑ Checking and adjusting
⇒ page 60
2 - Hexagon socket head bolt,
20 Nm
3 - Hexagon bolt, 20 Nm
4 - Nut insert
5 - Mounting bracket
6 - Hexagon bolt, 20 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
respect to the correctness of information in this document. Copyright by SEAT S.A.

4. Assembly overview: Brake pressure regulator 59

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

5 Checking and adjusting brake pres‐

sure regulator
Special tools and workshop equipment required
♦ Brake system test unit -V.A.G 1310 A-

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.

60 Rep. Gr. 47 - Brakes, Brake hydraulics

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

The brake pressure regulator is mounted on a bracket which is in

turn fixed to a rear axle mounting bracket and is controlled from
the rear axle by a spring.
Checking operation
Firmly depress the brake pedal and release quickly (vehicle
standing on its wheels). This must cause the brake pressure reg‐
ulator lever to move.
Checking and adjusting pressure

Note!

The brake pressure regulator is set with the vehicle unladened

10)
.

– Lift vehicle and connect the pressure gauges to front left brake
caliper and to the rear right wheel cylinder.
– Bleed both gauges.
10) The term “unladen” means: The weight of the vehicle ready for the road (full
fuel tank, spare wheel, tool kit and jack).

– Lower vehicle and bounce the rear of the vehicle several

times.
– Depress brake pedal and measure pressures.
– Compare figures attained with specifications ⇒ page 61 and
if necessary adjust.
Adjusting regulator
Rear axle test pressure too high:
– Release regulator spring.
Rear axle test pressures too low:
– Tension regulator spring.

Note!

Do not adjust with brake pedal depressed, therefore observe the

following sequence:

– Read off figures.

– Release pedal.
– Adjust spring.
– Depress pedal again.
– Read off figures and if necessary, readjust.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Remove
permitted pressure
unless authorised by SEATgauges
S.A. SEATand bleed
S.A does brakeorsystem
not guarantee accept any liability with
⇒ page
respect 63correctness
to the . of information in this document. Copyright by SEAT S.A.

5.1 Load dependent brake pressure regula‐

tor specifications
For all vehicles except those with 1.6 l or TDI engine
Model / Version bar bar
Drum brakes or disc Front axle 50 Front axle 100
brakes

5. Checking and adjusting brake pressure regulator 61

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

Model / Version bar bar

on rear axle Rear axle 24 ... 30 Rear axle 46 ... 52

Only vehicles with 1.6 l or TDI engine

Model / Version bar bar
Drum brakes or disc Front axle 50 Front axle 100
brakes
on rear axle Rear axle 19 ... 25 Rear axle 34 ... 40

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.

62 Rep. Gr. 47 - Brakes, Brake hydraulics

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

6 Bleeding braking system on vehicles

with and without ABS
The bleeding of the brake system is described for Brake filling and
bleeder unit -SAT 1150- .
Special point regarding vehicles with ABS/EDL
When at least one chamber in the brake fluid reservoir is com‐
pletely empty (e.g. leaks in braking system) the hydraulic unit
must be bled with fault reader -V.A.G 1551- in function “basic
setting” .

Caution

When filling with brake fluid using brake filling and bleeder unit
-SAT 1150- , it is essential to ensure that the filling pressure of
1 bar is not exceeded.

Therefore the filling pressure on brake filling and bleeder unit -

SAT 1150- must be regulated down to 1 bar ⇒ Operating Instruc‐
tions -SAT 1150- .
If the filling pressure exceeds 1 bar it cannot be guaranteed that
the hydraulic unit is bled sufficiently.
Introduction of basic setting
⇒ VAS 5051

Note!
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
♦ Bleeding the braking system on
permitted vehicles
unless with
authorised ABS
by SEAT isSEAT
S.A. carried
S.A does not guarantee or accept any liability with

out as for vehicles with conventional braking systems.

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

♦ On non-ABS vehicles with a brake pressure regulator, move

the regulator lever when bleeding rear brakes.
♦ Use new brake fluid with part No. -B 000 700 A .- (Enter con‐
tainer index for decimal point).
♦ Brake fluid is poisonous. Also due to its corrosive effect brake
fluid must not come into contact with paintwork.
♦ Brake fluid is hygroscopic, which means it absorbs moisture
from the ambient air and should therefore always be stored in
air tight containers.
♦ Rinse off brake fluid spillages, by using plenty of water.

6.1 Bleeding brakes with Brake filling and

bleeder unit -SAT 1150-
Special tools and workshop equipment required

6. Bleeding braking system on vehicles with and without ABS 63

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

♦ Brake filling and bleeder unit -SAT 1150-

Note!

Bleeding the brake system on vehicles with ABS is performed in

same way as vehicles with a conventional brake system.

– Connect brake filling and bleeder unit -SAT 1150- .

– Open bleed screws in the specified order and bleed brake cal‐
ipers and wheel cylinders.
Bleeding sequence
1- Rear right wheel cylinder/brake caliper
2- Rear left wheel cylinder/brake caliper
3- Front right brake caliper
4- Front left brake caliper
Vehicles with ABS or ABS/EDL
With these vehicles a test drive must be carried out after bleeding
brakes. When doing this an ABS regulation must be performed at
least once!

Note!

Move brake pressure regulator lever when bleeding rear brakes

on vehicles with a brake pressure regulator.

6.2 Bleeding brake system without brake fill‐

ing and bleeding appliance
– Build-up brake pressure in brake system by pumping the brake
pedal.
– Attach bleeder bottle hose and open bleed screw.
– With brake pedal held down, close bleed screw.
– Repeat operation until no air is present.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
Bleeding sequence ⇒ page 64 unless authorised by SEAT S.A. SEAT S.A does not guarantee or accept any liability with
permitted
respect to the correctness of information in this document. Copyright by SEAT S.A.
Changing brake fluid
⇒ Maintenance ; Booklet

64 Rep. Gr. 47 - Brakes, Brake hydraulics

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7 Assembly overview: brake master cylinder/brake servo

Note!

Complete master cylinders and brake servos can be replaced independently of each other.

1 - Self-locking hexagon nut,

25 Nm
2 - Brake servo
❑ On petrol engines the
vacuum required is tak‐
en from the intake mani‐
fold.
❑ On Diesel engines an
exhauster is installed to
create the required vac‐
uum.
❑ Functional check
– With engine switched
off, depress brake pedal
firmly several times (to
exhaust the vacuum in
the unit).

– Now depress brake

pedal with average foot
pressure, hold and start
engine. If the servo unit
is working properly, the
pedal will be felt to give
slightly under foot (ser‐
vo assistance becomes
effective).
❑ Separating from brake
pedal ⇒ page 48 .
❑ Non-return valve (in
vacuum hose)
⇒ page 67
Functional check ⇒ page 67

3 - Sealing ring 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
❑ Renew respect to the correctness of information in this document. Copyright by SEAT S.A.

4 - Self-locking hexagon nut, 20 Nm

5 - Brake master cylinder
❑ Cannot be repaired. If faulty, renew complete.
6 - Heat shield
❑ Only vehicles with certain engines.
7 - Self-locking hexagon nut, 20 Nm
8 - Sealing plug
❑ Moisten with brake fluid and press into reservoir

7. Assembly overview: brake master cylinder/brake servo 65

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
Brake systems - Edition 05.99

9 - Brake fluid reservoir, LHD

10 - Seal
11 - Cap with switch for brake fluid level
12 - Vacuum hose
❑ With non-return valve
Functional check ⇒ page 67

13 - Brake fluid reservoir, RHD

7.1 Removing and installing vacuum pump

for brake servo (Diesel vehicles)

7.1.1 Removing
– Remove retainer for wiring loom from vacuum pump.
– Loosen vacuum hose securing clamp -arrow A- and pull hose
off.
– Remove bolt -arrows B- on cylinder head flange.
– Remove vacuum pump.
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!

The vacuum pump cannot be serviced.

7.1.2 Installing

Note!

When inserting vacuum pump ensure follower engages correctly

with camshaft.

– Fit bolts -arrows B- on cylinder head flange and secure vac‐

uum hose with clamp -arrow A- .

66 Rep. Gr. 47 - Brakes, Brake hydraulics

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– Checking non-return valve -A- .

Air must pass through valve in -direction of arrow- .
Valve must remain closed in opposite direction.
Observe correct installation position.

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.

7. Assembly overview: brake master cylinder/brake servo 67

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
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8 Removing and installing brake mas‐

ter cylinder

8.1 Removing and installing brake master

cylinder

8.1.1 Removing
– Note or request radio code on vehicles with coded radio if
necessary.
– Disconnect battery.
Vehicles with ABS or ABS/EDL
– Remove control unit and hydraulic unit ⇒ page 14 .
Continued for all vehicles
– Lay out sufficient lint free clothes in area of plenum chamber,
engine and gearbox.
– Draw off as much brake fluid as possible from brake fluid res‐
ervoir using a suction bottle.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
– Pull connector off brake fluid level switch.
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.
– Disconnect brake pipes on brake master cylinder and seal
brake pipes with plugs from repair kit -1H0 698 311 A- .
– Unscrew brake master cylinder nuts.
– Carefully take brake master cylinder out of brake servo unit.

8.1.2 Installing
Install in reverse order.
Observe the following points when installing:
– When fitting together the brake master cylinder and brake ser‐
vo unit, ensure that the push rod is correctly located in the
brake master cylinder.
– After installing, bleed brake system ⇒ page 63 .

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9 Removing and installing brake servo

9.1 Removing and installing brake servo

Note!

Removing and installing the brake servo can deviate from the fol‐
lowing description slightly, this will depend on engine and equip‐
ment level.

9.1.1 Removing
– Note or request radio code on vehicles with coded radio if
necessary.
– Disconnect and remove battery.
– Pull connector off brake fluid level switch.
– Remove coolant expansion tank, pull off plug and swing to
side.
– Disconnect vacuum hose from brake servo.
– Unbolt both mountings of the clutch cable.
Vehicles with ABS or ABS/EDL
– Remove control unit and hydraulic unit ⇒ page 14 .
Vehicles without ABS or ABS/EDL
– Disconnect brake pipes on brake master cylinder and seal
brake pipes with plugs from repair kit -1H0 698 311 A- .
Continued for all vehicles
– Remove trim below dash panel.
– Remove brake light switch.
– Remove brake pedal switch -F47- .
– Separate brake pedal from brake servo ⇒ page 48 .
– Unbolt brake servo.
– Guide brake servo with brake master cylinder out forwards and
remove.

9.1.2 Installing
Install in reverse order.
– Adjust brake light switch ⇒ page 49 .
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– Install brake pedal switch -F47-permitted
and adjust ⇒ Rep.
unless authorised Gr. S.A.
by SEAT 24 SEAT
; S.A does not guarantee or accept any liability with
Checking additional signals . respect to the correctness of information in this document. Copyright by SEAT S.A.

– After installing, bleed brake system ⇒ page 63 .

9. Removing and installing brake servo 69

 Ibiza, Córdoba, Córdoba Vario 1999 ➤
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10 Definitions
These explanations refer only to this assembly group: Brake sys‐
tem. These definitions are not necessarily valid generally.
ABS
The anti-lock brake system (ABS) is a regulating system in the
brake system that prevents the wheels from locking when braking.
ABS/EDL
Anti-lock brake system with electronic differential lock (type of
traction control system).
Speed sensor
The speed sensor sends the speed signal to the control unit.
Performing self-diagnosis
Connecting fault reader unit to read fault memory.

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.

70 Rep. Gr. 47 - Brakes, Brake hydraulics