Service

Workshop Manual
Roomster 2006 ➤
Brake systems
Edition 02.2014

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

Service Department. Technical Information

 Service
List of Workshop Manual Repair Groups

Repair Group
00 - Technical data
45 - Anti-lock brake system
46 - Brakes - mechanism
47 - Brakes - hydraulics

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

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 ŠKODA AUTO a. s. D3E80500BB8

 Roomster 2006 ➤
Brake systems - Edition 02.2014

Contents

00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Brake variants and their assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

45 - Anti-lock brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1 Antilock braking system (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1 Instructions for repair work on Antilock braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 Distinguishing features of the ABS systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3 Basic information on fault finding and on repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.4 Distinguishing features of the control units for ABS and ESP BOSCH 8.0 . . . . . . . . . . . . 18
2 Perform self-diagnosis - ABS BOSCH 8.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.1 Test conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.2 Connecting vehicle diagnosis, measurement and information system VAS and selecting
function (ABS system BOSCH 8.0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3 Basic setting of the ABS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.1 Basic setting - ABS BOSCH 8.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.2 Basic setting - ABS BOSCH 8.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3 Basic setting - ABS/TCS/ESP BOSCH 8.2i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.4 Null balance of the steering angle sender G85 (vehicles with ABS/TCS/ESP BOSCH 8.0 and
ABS/TCS/ESP BOSCH 8.2i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.5 Performing ESP road and system test (vehicles with ABS/TCS/ESP BOSCH 8.0) . . . . . . 23
4 Electric/electronic components and fitting locations ABS/ESP . . . . . . . . . . . . . . . . . . . . . . 24
4.1 Overview - electric/electronic components and fitting locations ABS/ESP BOSCH 8.0 . . 24
4.2 Electric/electronic components and fitting locations ABS/ESP BOSCH 8.0 . . . . . . . . . . . . 27
4.3 Electric/electronic components and fitting locations ABS/EDL/TCS/ESP BOSCH 8.2i . . . . 28
5 Indication of faults by means of warning lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.1 ABS/TCS/ESP BOSCH 8.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.2 ABS BOSCH 8.2/8.2i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6 Hydraulic control unit (ABS systems BOSCH 8.0), brake servo unit/master brake cylinder
........................................................................ 37
6.1 Summary of components of control unit, brake servo unit and master brake cylinder . . . . 37
6.2 Removing and installing hydraulic control unit ABS BOSCH 8.0 - left-hand drive . . . . . . . . 40
6.3 Removing and installing hydraulic control unit ABS BOSCH 8.0 - vehicles - right-hand
drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.4 Removing and installing the ABS control unit bracket BOSCH 8.0 . . . . . . . . . . . . . . . . . . 48
6.5 Connect the brake lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7 Removing and installing parts of the ABS System on the front and rear axle . . . . . . . . . . 54
7.1 Removing and installing the ABS speed sensor on the front axle . . . . . . . . . . . . . . . . . . . . 54
7.2 Removing and installing front wheel speed sensor cables - Vehicles with ABS BOSCH 8.0
........................................................................ 56
7.3 Removing and installing the ABS speed sensor on the rear axle - vehicles up to 11/2012.
........................................................................ 60
7.4 Removing and installing the ABS speed sensor on the rear axle - vehicles as of 11/2012.
........................................................................ 62
7.5 Repairing rear ABS wheel speed sensor cables - Vehicles with ABS BOSCH 8.0 . . . . . . 64
8 Removing and installing parts of the ESP System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.1 Removing and installing sensor unit for ESP G419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
8.2 Removing and installing steering angle sender G85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
69
9 ABS BOSCH 8.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
70
9.1 Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder
ABS BOSCH 8.2 - left-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Contents i
 Roomster 2006 ➤
Brake systems - Edition 02.2014

9.2 Connection of the brake lines from the master brake cylinder to the hydraulic unit ABS
BOSCH 8.2 - left-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
9.3 Removing and installing control unit and hydraulic unit ABS BOSCH 8.2 - left-hand drive
........................................................................ 72
9.4 Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder
ABS BOSCH 8.2 - right-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
9.5 Connection of the brake lines from the master brake cylinder to the hydraulic unit ABS
BOSCH 8.2 - right-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
9.6 Removing and installing control unit and hydraulic unit ABS BOSCH 8.2 - right-hand drive
........................................................................ 76
10 ABS/EDL/TCS/ESP BOSCH 8.2i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
10.1 Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder
ABS/EDL/TCS/ESP BOSCH 8.2i - left-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
10.2 Connection of the brake lines from the master brake cylinder to the hydraulic unit ABS/EDL/
TCS/ESP BOSCH 8.2i - left-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
10.3 Remove and install control unit and hydraulic unit ABS/EDL/TCS/ESP BOSCH 8.2i - left-hand
drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
10.4 Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Master Brake Cylinder
ABS/EDL/TCS/ESP BOSCH 8.2i - right-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
10.5 Connection of the brake lines from the master brake cylinder to the hydraulic unit ABS/EDL/
TCS/ESP BOSCH 8.2i - right-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
10.6 Remove and install control unit and hydraulic unit ABS/EDL/TCS/ESP BOSCH 8.2i - right-
hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

46 - Brakes - mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1 Repairing front wheel brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
1.1 Changing the brake pads of the front brake - Mounting instructions . . . . . . . . . . . . . . . . . . 92
1.2 Repairing front wheel brake - Floating caliper disc brake FS-IIl . . . . . . . . . . . . . . . . . . . . . . 92
1.3 Removing and installing brake pads and floating caliper disc brake FS-III . . . . . . . . . . . . 94
1.4 Repairing front wheel brake - Floating caliper disc brake C54 . . . . . . . . . . . . . . . . . . . . . . 99
1.5 Removing and installing brake pads and floating caliper disc brake C54 . . . . . . . . . . . . . . 102
1.6 Repairing front wheel brake, brake caliper FN3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
1.7 Removing and installing brake pads for brake caliper FN3 . . . . . . . . . . . . . . . . . . . . . . . . 106
1.8 Removing and installing brake caliper FN3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
2 Repairing rear brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.1 Replacing the brake shoes of the rear brake - Mounting instructions . . . . . . . . . . . . . . . . 112
2.2 Removing and installing rear brake - Drum brake up to 44.2012 . . . . . . . . . . . . . . . . . . . . 112
2.3 Repairing rear brake - Drum brake up to 44.2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.4 Removing and installing brake shoes - Drum brake up to 44.2012 . . . . . . . . . . . . . . . . . . 116
2.5 Removing and installing rear brake - Drum brake from 45.2012 . . . . . . . . . . . . . . . . . . . . 120
2.6 Repairing rear brakeunless
- Drum brake from 45.2012 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
123
2.7 Removing and installing with brake
respect toshoes - Drum
the correctness brake infrom
of information 45.2012
this document. . . .by.ŠKODA
Copyright . . . .AUTO
. . . A.. S.�
...... 126
2.8 Testing wheel-brake cylinder for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.9 Changing the brake pads of the rear wheel disc brake - Mounting instructions . . . . . . . . . . 131
2.10 Removing and installing rear brake - Disc brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.11 Removing and installing brake pads - Rear disc brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
3 Handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3.1 Assembly overview of the handbrake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3.2 Removing and installing the hand-brake cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3.3 Setting the hand-brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4 Foot Controls, Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.1 Summary of components of foot controls, brake pedal up to MY 2010 . . . . . . . . . . . . . . . . 144
4.2 Setting, removing and installing the brake light switch F and brake pedal switch F47 up to
MY 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.3 Separating the brake pedal from the brake servo unit and clipping up to MY 2010 . . . . . . 146
4.4 Removing and installing the foot controls up to MY 2010 - left-hand drive . . . . . . . . . . . . 147
4.5 Removing and installing the pedals up to MY 2010 - left-hand drive . . . . . . . . . . . . . . . . . . 151
4.6 Removing and installing the pedals up to MY 2010 - right-hand drive . . . . . . . . . . . . . . . . 154

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 Roomster 2006 ➤
Brake systems - Edition 02.2014

4.7 Summary of components: Brake pedal from MY 2011 - left-hand drive . . . . . . . . . . . . . . . . 157
4.8 Separating the brake pedal from the brake servo unit and clipping as of MY 2011 . . . . . . 157
4.9 Removing and installing the foot controls from MY 2011 - left-hand drive . . . . . . . . . . . . . . 158
4.10 Removing and installing the brake pedal from MY 2011 - left-hand drive . . . . . . . . . . . . . . 159
4.11 Summary of components: Brake pedal from MY 2011 - right-hand drive . . . . . . . . . . . . . . 159
4.12 Removing and installing the foot controls from MY 2011 - right-hand drive . . . . . . . . . . . . 161
4.13 Removing and installing the brake pedals from MY 2011 - right-hand drive . . . . . . . . . . . . 161

47 - Brakes - hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

1 Repairing brake caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
1.1 Summary of components of the brake caliper of the FS-III brake at the front . . . . . . . . . . 163
1.2 Removing and installing brake caliper piston of front FS-III brake . . . . . . . . . . . . . . . . . . . . 164
1.3 Summary of components of the brake caliper of the C54 brake at the front . . . . . . . . . . . . 166
1.4 Removing and installing brake caliper piston of front C54 brake . . . . . . . . . . . . . . . . . . . . 167
1.5 Repairing brake caliper FN3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
1.6 Removing and installing brake caliper piston FN3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
1.7 Summary of components of the brake caliper of the brake at the rear . . . . . . . . . . . . . . . . 170
1.8 Removing and installing brake caliper piston of rear brake . . . . . . . . . . . . . . . . . . . . . . . . 171
2 Brake Servo Unit, Master Brake Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
2.1 Summary of components of brake servo unit, master brake cylinder up to MY 2010 . . . . 173
2.2 Summary of components of brake servo unit, master brake cylinder as of MY 2011 - left-hand
drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
2.3 Summary of components of brake servo unit, master brake cylinder as of MY 2011 - right-
hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
2.4 Brake light switch F as of MY 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
2.5 Checking the master brake cylinder for tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
2.6 Removing and installing master brake cylinder - left-hand drive . . . . . . . . . . . . . . . . . . . . 181
2.7 Removing and installing master brake cylinder - right-hand drive . . . . . . . . . . . . . . . . . . . . 185
2.8 Removing and installing brake servo unit - left-hand drive . . . . . . . . . . . . . . . . . . . . . . . . . . 189
2.9 Removing and installing brake servo unit - right-hand drive . . . . . . . . . . . . . . . . . . . . . . . . 191
2.10 Checking the non-return valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
2.11 Removing and installing tandem pump for fuel and vacuum supply . . . . . . . . . . . . . . . . . . 192
2.12 Removing and installing the vacuum pump for the vacuum supply . . . . . . . . . . . . . . . . . . 193
3 Checking vacuum system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3.1 Connecting vacuum gauge for brake servo VAS 6721 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3.2 Checking vacuum generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.3 Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
3.4 Vacuum generation withunless manual
Protected vacuum
by copyright. pump
Copying VASor6213
for private commercial . .purposes,
. . . . .in. part
. . or. .in.whole,
. . . is. .not. permitted
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
..... 197
4 Bleeding brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.. S.�
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO ... 198
4.1 Bleeding the hydraulic unit (vehicles with ESP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
4.2 Bleeding the brake system using the brake filling and bleeding device , e.g. VAS 5234 VAS
5234 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.3 Bleeding the brake system of air without using the brake filling and bleeding device . . . . 200
4.4 Change brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
5 Brake-power regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5.1 Summary of components of brake-power regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
5.2 Inspecting, setting brake-power regulator and adjusting values . . . . . . . . . . . . . . . . . . . . 203
5.3 Removing and installing brake-power regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Contents iii
 Roomster 2006 ➤
Brake systems - Edition 02.2014

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

iv Contents
 Roomster 2006 ➤
Brake systems - Edition 02.2014

00 – Technical data
1 Brakes
(SRL000673; Edition 02.2014)
⇒ “1.1 Brake variants and their assignment”, page 1
⇒ “1.2 Brake fluid”, page 13

1.1 Brake variants and their assignment

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

1. Brakes 1
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Engine 1,2/47 kW 1,2/51 kW 1,4/63 kW 1,6/77 kW

Engine code letters: BME BZG BUD, BXW BTS
Master brake mm 20.64
cylinder - ∅
Brake servo Inch Left-hand drive with and without ABS: 8.5
unit - ∅ Right-hand drive with and without ABS: 8.5
♦ Front disc brake:

Front brake caliper (type de‐ FS-III C54 FS-III C54 FS-III C54 C54
nomination)
Front brake cal‐ mm 54.0 54.0 54.0 54.0 54.0 54.0 54.0
iper, piston - ∅
Front brake mm 256.0 288.0 256.0 288.0 256.0 288.0 288.0
disc - ∅
Brake disc, mm 22.0 25.0 22.0 25.0 22.0 25.0 25.0
thickness
Brake disc, min‐ mm 19.0 22.0 19.0 22.0 19.0 22.0 22.0
imum thickness
Pad thickness mm 19.6 18.6 19.6 18.6 19.6 18.6 18.6
with supporting
plate
Minimum pad mm 2.0 2.0 2.0 2.0 2.0 2.0 2.0
thickness with‐
out supporting
plate
♦ Rear drum brake: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Brake drum - ∅ mm 230.03) 230.03) 230.03) 230.03)
228.04) 228.04) 228.04) 228.04)
Brake drum - mm 231.03) 231.03) 231.03) 231.03)
maximum di‐ 230.04) 230.04) 230.04) 230.04)
ameter ∅
Wheel-brake mm 19.05 19.05 19.05 19.05
cylinder - ∅
Brake pad, mm 32.0 32.0 32.0 32.0
width

2
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Engine 1,2/47 kW 1,2/51 kW 1,4/63 kW 1,6/77 kW

Engine code letters: BME BZG BUD, BXW BTS
Pad thickness mm 5.53) 5.53) 5.53) 5.53)
without sup‐ 4.44) 4.44) 4.44) 4.44)
porting shoe
Minimum pad mm 2.53) 2.53) 2.53) 2.53)
thickness with‐ 14) 14) 14) 14)
out supporting
plate
♦ Rear disc brake:

Rear brake cal‐ - - C38 C38

iper (type de‐
nomination)
Rear brake cal‐ mm - - 38.0 38.0
iper, piston - ∅
Rear brake disc mm - - 232.01) 232.01)
-∅ 230.02) 230.02)
Brake disc, mm - - 9.0 9.0
thickness
Brake disc, min‐ mm - - 7.0 7.0
imum thickness
Pad thickness mm - - 16.9 16.9
with supporting
plate
Minimum pad mm - - 2.0 2.0
thickness with‐ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
out supporting unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
plate
1) valid for vehicles up to 05.2009
2) valid for vehicles as of 06.2009
3) valid for vehicles up to 44.2012
4) valid for vehicles as of 45.2012

3
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Engine 1,4/51 kW TDI PD 1,4/59 kW TDI PD 1,9/77 kW TDI PD

Engine code letters: BNM BNV, BMS AXR, BSW, BLS
Master brake cylin‐ mm 20.64
der - ∅
Brake servo unit - ∅ Inch Left-hand drive with and without ABS: 8.5
Right-hand drive with and without ABS: 8.5
♦ Front disc brake:

Front brake caliper (type denomination) FS-III C54 C54 C54

Front brake caliper, mm 54.0 54.0 54.0 54.0
piston - ∅
Front brake disc - ∅ mm 256.0 288.0 288.0 288.0
Brake disc, thickness mm 22.0 25.0 25.0 25.0
Brake disc, minimum mm 19.0 22.0 22.0 22.0
thickness
Pad thickness with mm 19.6 18.6 18.6 18.6
supporting plate
Minimum pad thick‐ mm 2.0 2.0 2.0 2.0
ness without sup‐
porting plate
♦ Rear drum brake:

Brake drum - ∅ mm 230.03) 230.03) 230.03)

228.04) 228.04) 228.04)
Brake drum - maxi‐ mm 231.03) 231.03) 231.03)
mum diameter ∅ 230.04) 230.04) 230.04)
Wheel-brake cylin‐ mm 19.05 19.05 19.05
der - ∅
Brake pad, width mm 32.0 32.0 32.0
Pad thickness with‐ mm 5.53) 5.53) 5.53)
out supporting shoe 4.44) 4.44) 4.44)
Minimum pad thick‐ mm 2.53) 2.53) 2.53)
ness without sup‐ 14) 14) 14)
porting plate
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ Rear disc brake: unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

4
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Engine 1,4/51 kW TDI PD 1,4/59 kW TDI PD 1,9/77 kW TDI PD

Engine code letters: BNM BNV, BMS AXR, BSW, BLS
Rear brake caliper - C38 C38
(type denomination)
Rear brake caliper, mm - 38.0 38.0
piston - ∅
Rear brake disc - ∅ mm - 232.01) 232.01)
230.02) 230.02)
Brake disc, thickness mm - 9.0 9.0
Brake disc, minimum mm - 7.0 7.0
thickness
Pad thickness with mm - 16.9 16.9
supporting plate
Minimum pad thick‐ mm - 2.0 2.0
ness without sup‐
porting plate
1) valid for vehicles up to 05.2009
2) valid for vehicles as of 06.2009
3) valid for vehicles up to 44.2012
4) valid for vehicles as of 45.2012
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Engine 1,2/51 kW 1,2/63 kW 1,2/77 kW

Engine code letters: CGPA CBZA CBZB
Vehicle type ROOMSTER, Praktik Roomster N1 ROOMSTER, Roomster N1 Roomster, Praktik, Room‐
Praktik ster N1
Master brake cyl‐ mm 22.22
inder - ∅
Brake servo unit - Inch Left-hand drive with and without ABS: 10
∅ Right-hand drive with ABS: 7"/8" - tandem
♦ Front disc brake:

5
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Engine 1,2/51 kW 1,2/63 kW 1,2/77 kW

Engine code letters: CGPA CBZA CBZB
Vehicle type ROOMSTER, Praktik Roomster N1 ROOMSTER, Roomster N1 Roomster, Praktik, Room‐
Praktik ster N1
Front brake caliper (type de‐ FS-III FN3 FS-III FN3 FN3
nomination)
Front brake cali‐ mm 54.0 54.0 54.0 54.0 54.0
per, piston - ∅
Front brake disc - mm 256.0 288.0 256.0 288.0 288.0
∅
Brake disc, thick‐ mm 22.0 25.0 22.0 25.0 25.0
ness
Brake disc, mini‐ mm 19.0 22.0 19.0 22.0 22.0
mum thickness
Pad thickness mm 19.6 20.6 19.6 20.6 20.6
with supporting
plate
Minimum pad mm 2.0 2.0 2.0 2.0 2.0
thickness without
supporting plate
♦ Rear drum brake:

Brake drum - ∅ mm 230.03) 230.03) 230.03)

228.04) 228.04) 228.04)
Brake drum - mm 231.03) 231.03) 231.03)
maximum diame‐ 230.04) 230.04) 230.04)
ter ∅
Wheel-brake cyl‐ mm 19.05 Protected by copyright. Copying for private or commercial 19.05 19.05
purposes, in part or in whole, is not permitted
inder - ∅ unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Brake pad, width mm 32.0 32.0 32.0
Pad thickness mm 5.53) 5.53) 5.53)
without support‐ 4.44) 4.44) 4.44)
ing shoe
Minimum pad mm 2.53) 2.53) 2.53)
thickness without 14) 14) 14)
supporting plate

6
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Engine 1,2/51 kW 1,2/63 kW 1,2/77 kW

Engine code letters: CGPA CBZA CBZB
Vehicle type ROOMSTER, Praktik Roomster N1 ROOMSTER, Roomster N1 Roomster, Praktik, Room‐
Praktik ster N1
♦ Rear disc brake:

Rear brake cali‐ - C38 C38

per (type de‐
nomination)
Rear brake cali‐ mm - 38.0 38.0
per, piston - ∅
Rear brake disc - mm - 230.0 230.0
∅
Brake disc, thick‐ mm - 9.0 9.0
ness
Brake disc, mini‐ mm - 7.0 7.0
mum thickness
Pad thickness mm - 16.9 16.9
with supporting
plate
Minimum pad mm - 2.0 2.0
thickness without
supporting plate
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
3) valid for vehicles up to 44.2012 unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
4) valid for vehicles as of 45.2012

Engine 1,4/63 kW 1,6/77 kW 1,2/55 kW TDI CR

Engine code letters: CGGB CFNA CFWA
Vehicle type ROOMSTER, Praktik Roomster N1 Roomster, Praktik, Roomster N1 Roomster, Praktik, Roomster N1
Master brake cylin‐ mm 22.22
der - ∅
Brake servo unit - ∅ Inch Left-hand drive with and without ABS: 10
Right-hand drive with ABS: 7"/8" - tandem

7
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Engine 1,4/63 kW 1,6/77 kW 1,2/55 kW TDI CR

Engine code letters: CGGB CFNA CFWA
Vehicle type ROOMSTER, Praktik Roomster N1 Roomster, Praktik, Roomster N1 Roomster, Praktik, Roomster N1
♦ Front disc brake:

Front brake caliper (type denomination) FS-III FN3 FN3 FN3

Front brake caliper, mm 54.0 54.0 54.0 54.0
piston - ∅
Front brake disc - ∅ mm 256.0 288.0 288.0 288.0
Brake disc, thick‐ mm 22.0 25.0 25.0 25.0
ness
Brake disc, mini‐ mm 19.0 22.0 22.0 22.0
mum thickness
Pad thickness with mm 19.6 20.6 20.6 20.6
supporting plate
Minimum pad thick‐ mm 2.0 2.0 2.0 2.0
ness without sup‐
porting plate
♦ Rear drum brake:

Brake drum - ∅ mm 230.03) 230.03) 230.03)

228.04) 228.04) 228.04)
Brake drum - maxi‐ mm 231.03) 231.03) 231.03)
mum diameter ∅ 230.04) 230.04) 230.04)
Wheel-brake cylin‐ mm 19.05 19.05 19.05
der - ∅
Brake pad, width mm Protected by copyright. Copying32.0 32.0
for private or commercial purposes, in part or in whole, is not permitted 32.0
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Pad thickness with‐ mm 5.5
with respect to the correctness 3)
of information in this document. Copyright by ŠKODA5.5AUTO3) A. S.� 5.53)
out supporting shoe 4.44) 4.44) 4.44)
Minimum pad thick‐ mm 2.53) 2.53) 2.53)
ness without sup‐ 14) 14) 14)
porting plate
♦ Rear disc brake:

Rear brake caliper C38 C38 C38

(type denomination)

8
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Engine 1,4/63 kW 1,6/77 kW 1,2/55 kW TDI CR

Engine code letters: CGGB CFNA CFWA
Vehicle type ROOMSTER, Praktik Roomster N1 Roomster, Praktik, Roomster N1 Roomster, Praktik, Roomster N1
Rear brake caliper, mm 38.0 38.0 38.0
piston - ∅
Rear brake disc - ∅ mm 230.0 230.0 230.0
Brake disc, thick‐ mm 9.0 9.0 9.0
ness
Brake disc, mini‐ mm 7.0 7.0 7.0
mum thickness
Pad thickness with mm 16.9 16.9 16.9
supporting plate
Minimum pad thick‐ mm 2.0 2.0 2.0
ness without sup‐
porting plate
3) valid for vehicles up to 44.2012
4) valid for vehicles as of 45.2012

Engine 1,6/55 kW TDI CR 1,6/66 kW TDI CR 1,6/77 kW TDI CR

Engine code letters: CFWA CAYB CAYC
Vehicle type Roomster, Praktik, Roomster, Praktik, Roomster N1 Roomster, Praktik, Roomster N1
Roomster N1
Master brake cylinder - ∅ mm 22.22
Brake servo unit - ∅ Inch Left-hand drive with and without ABS: 10
Right-hand drive with ABS: 7"/8" - tandem
♦ Front disc brake:

Front brake caliper (type denomination) FN3 Protected by copyright. Copying for privateFN3
or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
FN3
Front brake caliper, pis‐ mm 54.0
with 54.0by ŠKODA AUTO A. S.�
respect to the correctness of information in this document. Copyright 54.0
ton - ∅
Front brake disc - ∅ mm 288.0 288.0 288.0
Brake disc, thickness mm 25.0 25.0 25.0

9
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Engine 1,6/55 kW TDI CR 1,6/66 kW TDI CR 1,6/77 kW TDI CR

Engine code letters: CFWA CAYB CAYC
Vehicle type Roomster, Praktik, Roomster, Praktik, Roomster N1 Roomster, Praktik, Roomster N1
Roomster N1
Brake disc, minimum mm 22.0 22.0 22.0
thickness
Pad thickness with sup‐ mm 20.6 20.6 20.6
porting plate
Minimum pad thickness mm 2.0 2.0 2.0
without supporting plate
♦ Rear drum brake:

Brake drum - ∅ mm 200.03) 200.03) 200.03)

201.04) 201.04) 201.04)
Brake drum - maximum mm 231.03) 231.03) 231.03)
diameter ∅ 230.04) 230.04) 230.04)
Wheel-brake cylinder - ∅ mm 19.05 19.05 19.05
Brake pad, width mm 40.03) 40.03) 40.03)
32.04) 32.04) 32.04)
Pad thickness without mm 5.03) 5.03) 5.03)
supporting shoe 4.44) 4.44) 4.44)
Minimum pad thickness mm 2.23) 2.23) 2.23)
without supporting plate 14) 14) 14)
♦ Rear disc brake:

Rear brake caliper (type C38 C38 C38

denomination)
Rear brake caliper, piston mm 38.0 38.0 purposes, in part or in whole, is not permitted
Protected by copyright. Copying for private or commercial 38.0
-∅ unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Rear brake disc - ∅ mm 230.0 230.0 230.0
Brake disc, thickness mm 9.0 9.0 9.0
Brake disc, minimum mm 7.0 7.0 7.0
thickness
Pad thickness with sup‐ mm 16.9 16.9 16.9
porting plate

10
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Engine 1,6/55 kW TDI CR 1,6/66 kW TDI CR 1,6/77 kW TDI CR

Engine code letters: CFWA CAYB CAYC
Vehicle type Roomster, Praktik, Roomster, Praktik, Roomster N1 Roomster, Praktik, Roomster N1
Roomster N1
Minimum pad thickness mm 2.0 2.0 2.0
without supporting plate
3) valid for vehicles up to 44.2012
4) valid for vehicles as of 45.2012

Engine 1,6/55 kW TDI CR

Engine code letters: CAYA
Vehicle type Roomster, Praktik, Room‐
ster N1
Master brake cylinder - ∅ mm 22.22
Brake servo unit - ∅ Inch Left-hand drive with and without ABS: 10
Right-hand drive with ABS: 7"/8" - tandem
♦ Front disc brake:

Front brake caliper (type denomination) FN3

Front brake caliper, piston mm 54.0
-∅
Front brake disc - ∅ mm 288.0
Brake disc, thickness mm 25.0
Brake disc, minimum thick‐ mm 22.0
ness
Pad thickness with sup‐ mm 20.6
porting plate
Minimum pad thickness mm 2.0
without supporting plate
♦ Rear drum brake: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Brake drum - ∅ mm 200.0 3) respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
with

201.04)

11
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Engine 1,6/55 kW TDI CR

Engine code letters: CAYA
Vehicle type Roomster, Praktik, Room‐
ster N1
Brake drum - maximum di‐ mm 231.03)
ameter ∅ 230.04)
Wheel-brake cylinder - ∅ mm 19.05
Brake pad, width mm 40.03)
32.04)
Pad thickness without sup‐ mm 5.03)
porting shoe 4.44)
Minimum pad thickness mm 2.23)
without supporting plate 14)
♦ Rear disc brake:

Rear brake caliper (type C38

denomination)
Rear brake caliper, piston - mm 38.0
∅
Rear brake disc - ∅ mm 230.0
Brake disc, thickness mm 9.0
Brake disc, minimum thick‐ mm 7.0
ness
Pad thickness with sup‐ mm 16.9
porting plate
Minimum pad thickness mm 2.0
without supporting plate Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
3) with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
valid for vehicles up to 44.2012
4) valid for vehicles as of 45.2012

12
 Roomster 2006 ➤
Brake systems - Edition 02.2014

1.2 Brake fluid

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

13
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Classification N 052 766 (USA standard FMVSS 571.116 DOT4)

VW 501 14
Filling capacity 0.520 ltr. Vehicles with rear disc brakes, with ABS
0.550 ltr. Vehicles with rear drum brakes, with ABS
0.480 ltr. Vehicles with rear drum brakes, without ABS
Top-up ⇒ Maintenance ; Booklet Roomster

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

14
 Roomster 2006 ➤
Brake systems - Edition 02.2014

45 – Anti-lock brake system

1 Antilock braking system (ABS)
⇒ “1.1 Instructions for repair work on Antilock braking system”,
page 15
⇒ “1.2 Distinguishing features of the ABS systems”, page 16
⇒ “1.3 Basic information on fault finding and on repairs”,
page 17
⇒ “1.4 Distinguishing features of the control units for ABS and
ESP BOSCH 8.0”, page 18

1.1 Instructions for repair work on Antilock

braking system
The antilock braking system (ABS) and ESP are vehicle safety
systems; detailed system knowledge is required for working on
such systems.
Testing and replacement or repairs should be carried out only by
personnel specially trained for ABS.
Problems related to the ABS affect the braking system and the
amplifier. The conventional brake system remains fully functional
also without ABS. One must reckon with a somewhat changed
braking characteristic. The rear wheels can block quite early on
after the ABS warning light lights up!
The brake system is split diagonally. The brake servo assistance
is provided pneumatically by the vacuum brake servo unit.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Vehicles fitted with ABS,unless
ABS/EDL/TCS
authorised by ŠKODAor ABS/EDL/TCS/ESP
AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
BOSCH 8.0 do not have awith mechanical brake pressure
respect to the correctness of informationregulator.
in this document. Copyright by ŠKODA AUTO A. S.�
Specifically matched software in the control unit, the electronic
brake pressure distribution (EBD) regulates the brake pressure
on the rear axle.
Required technical information:
• Binder: “Current Flow Diagrams, Electrical Fault Finding and
Fitting Locations”
• Self-study programme ESP No. 42
• Technical Service Handbook
• Operating instruction of the Diagnostic unit - VAS-
♦ Before commencing work on the ABS systems, it is necessary
to interrogate the fault memory in order to check complaints
and conduct specific fault finding ⇒ Vehicle diagnostic tester.
♦ Do not separate plug connections unless the ignition is switch‐
ed off.
♦ Before commencing work on the ABS systems, switch off the
ignition and disconnect the earth strap at the battery ⇒ Elec‐
trical System; Rep. gr. 27 .
♦ If the battery earth strap is disconnected and connected, carry
out additional operations ⇒ Electrical System; Rep. gr. 27 .
♦ Welding work using electric welding equipment may affect the
ABS system.
♦ Before commencing welding work using electrical welding
tool:

1. Antilock braking system (ABS) 15

 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Disconnect the cable from the negative terminal of the battery

and cover the negative terminal.
– Connect the earth connection of the electric welding tool di‐
rectly to the part to be welded. There must not be any electri‐
cally insulated parts between the earth connection and the
welding point.
– Electronic control units and electrical wiring must not touch the
earth connection or the welding electrode.
♦ During painting operations, the electronic control unit can be
exposed to a maximum temperature of 95°C for only a short
period, and to a maximum of 85°C for longer periods (approx.
2 hours).
♦ Do not drive the vehicle if the connector is unplugged from the
control unit.
♦ When carrying out work on the antilock brake system, ensure
scrupulous cleanliness, on no account use agents containing
mineral oils, such as oil, greases, etc.
♦ Thoroughly clean connection points and the surrounding area
before disconnecting, but do not use any aggressive cleaning
agents, such as brake cleaner, petroleum, thinner or similar.
♦ Place removed parts on a clean surface and cover.
♦ Carefully cover or seal opened components if the repairs are
not carried out immediately (use plugs from repair kit 1HO 698
311 A).
♦ Do not use fluffy cloths.
♦ Remove spare parts from their wrapping immediately before
fitting.
♦ Use only genuine wrapped parts.
♦ When the system is open, do not work with compressed air
and do not move the vehicle.
♦ Ensure that no brake fluid is able to flow into the connectors.
♦ Observe the current regulations when handling brake fluid
⇒ page 198 .
♦ After completing work which involved opening the brake sys‐
tem, bleed brake system with brake filling and bleeding de‐
vice , e.g. -VAS 5234- , -VAS 5234- ⇒ page 199 .
♦ During the final road test, ensure that at least one controlled
brake application is performed (pulsing must be felt on the
brake pedal).
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
1.2 Distinguishing features of the ABS sys‐
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
tems
♦ ABS - wheel control system when braking. It prevents the
wheels from locking during a brake application initiated by the
driver.
♦ ESP - electronic stability program. It recognizes critical driving
conditions and stabilizes the vehicle by individual wheel brak‐
ing and by intervention in the engine control. This occurs
independently of the brake or accelerator pedal activation.
♦ EDL - electronic differential lock is a starting-off aid. A sup‐
porting torque is created for the differential gear by electroni‐
cally controlling the braking of the driven wheel which is
slipping. The engine power is thus available for the gripping
wheel with the better adhesion. This also applies when re‐
versing.

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

 Roomster 2006 ➤
Brake systems - Edition 02.2014

♦ TCS - traction control system. Prevents the driving wheels

from slipping when accelerating by throttling the engine power
output. This is possible over the entire vehicle speed range.
EDL and TCS are mutually supportive when accelerating the
vehicle.
♦ MBA - mechanical brake assistance.
♦ HBA - hydraulic brake assistance.
♦ EDC - Engine Drag Torque Control. Prevents the driving
wheels from locking, if suddenly the accelerator pedal is re‐
leased or when braking with a gear engaged.
♦ EBD - electronic brake pressure distribution.
♦ ASC - automatic steering control. Recommends to the driver
a change in the steering position, which under certain condi‐
tions can increase the efficiency of the ESP.
♦ HHC - Hill Hold Control. It enables an easy driving off on up‐
hills, without the vehicle rolling back and also without operating
the locking brake.
♦ TPM (RKA) - System for tyre pressure inspection
♦ RKA (TPM) - Tyre inspection display
♦ BPS - hydraulic assistance of the brake servo unit. Ensures
the brake pressure increase in case of emergencies for ex‐
ample during numerous or steadily forceful brake applications.
♦ RBS - Brake disc dryer system. By means of briefly braking
(unnoticeable to the driver) it ensures that the brake discs of
the front wheels are dry and clean during rainy weather.
♦ TSA - Trailer Stability Assist. The vehicle tension stability sys‐
tem is a Software upgrade of the brake and stabilisation
program ESP which avoids the dangerous swaying of the trail‐
er.

1.3 Basic information on fault finding and on

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

ABS BOSCH 8.0

As the control units are interlinked over two CAN bus lines, always
start fault finding by interrogating the contents of the fault mem‐
ories of all the control units fitted to the vehicle.
The interrogation of the fault memory is performed with the vehi‐
cle diagnosis, measurement and information system - VAS-
⇒ page 20 .
When doing so check whether a possibly stored fault might affect
the ABS system.
The ABS control unit - J104- together with the hydraulic unit for
ABS - N55- forms a compact unit. The control unit is equipped
with a fault memory. The connection for the self-diagnosis is lo‐
cated below the left steering wheel from the fuse carrier.
Self-diagnosis relates to the electrical/electronic part of the ABS,
i. e. faults are detected only over the electrical connection to the
control unit (e.g. open circuit to a wheel speed sensor).
The control unit detects faults while the vehicle is being operated
and stores them in a permanent memory,
whose information is retained even if the battery voltage is dis‐
connected. Faults which occur sporadically (isolated) are likewise
detected and stored. If this fault no longer occurs during 40 vehi‐
cle starts and driving-off procedures, it is erased from the fault

1. Antilock braking system (ABS) 17

 Roomster 2006 ➤
Brake systems - Edition 02.2014

memory (fault delete counter), with the exception of the fault

“Control unit defective”.
After the ignition is switched on the ABS warning light - K47- , the
red dual circuit and hand brake system warning light - K7- and the
traction control system warning light - K86- or the ESP and TCS
warning light - K155- light up for approx. 2 seconds.
During this period a test sequence (self-check) is performed in the
control unit with the following functions:
♦ Checking the supply voltage, minimum 11.0 volt
♦ Test of control unit including valve coils
♦ electrical test of wheel speed sensors; not fully completed until
vehicle reaches 20 km/h
♦ Check of control unit coding
♦ Test of electric motor for the return flow pump
Systematically initiate self-diagnosis at the start of fault finding
and retrieve the stored information using vehicle system tester -
VAS- ⇒ page 20

1.4 Distinguishing features of the control

units for ABS and ESP BOSCH 8.0
Fitting position of the system BOSCH 8.0
Arrangement of the ABS on left-hand drive vehicles.
1 - Hydraulic control unit
2 - Brake servo unit

Arrangement of the ABS on right-hand drive vehicles.

1 - Brake servo unit
2 - Hydraulic control unit

Note

Identification and assignment of the ABS systems ⇒ Electronic

catalogue of original parts

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

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

 Roomster 2006 ➤
Brake systems - Edition 02.2014

ABS, ABS/TCS BOSCH 8.0

♦ Dimension -a-: 80 mm
♦ Inscription “ABS” on the hydraulic unit for ABS - N55-
♦ 8 valve domes
♦ Control unit identification: The control unit version can be in‐
dicated with the vehicle diagnosis, measurement and infor‐
mation system - VAS- ⇒ page 20

ABS/TCS/ESP BOSCH 8.0

The hydraulic control unit ABS/TCS/ESP BOSCH 8.0 must not be
disassembled. It must be replaced as a complete unit in the case
of repairs.
♦ Dimension -a-: 103 mm
♦ Inscription “ESP” on the hydraulic unit for ABS - N55-
♦ 12 valve domes
♦ Control unit identification: The control unit version can be in‐
dicated with the vehicle diagnosis, measurement and infor‐
mation system - VAS- ⇒ page 20

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

1. Antilock braking system (ABS) 19

 Roomster 2006 ➤
Brake systems - Edition 02.2014

2 Perform self-diagnosis - ABS

BOSCH 8.0
⇒ “2.1 Test conditions”, page 20
⇒ “2.2 Connecting vehicle diagnosis, measurement and informa‐
tion system VAS and selecting function (ABS system BOSCH
8.0)”, page 20

2.1 Test conditions

• Approved tyre size fitted to all wheels; Tyres inflated to the
specified tyre pressure.
• Mechanical/hydraulic part of the brake system together with
the brake light switch and brake lights operating properly.
• No leaks in hydraulic connections and lines (visual inspection
of hydraulic unit, brake calipers, wheel brake cylinders, tan‐
dem brake master cylinder).
• Wheel bearings and wheel bearing play O.K.
• Plug connection on ABS control unit - J104- correctly plugged
in (lock is engaged).
• Inspect plug contacts of ABS components for connection and
correct fitting.
• All fuses must be OK in compliance with the current flow dia‐
gram.
• Battery voltage at least 11 V.

2.2 Connecting vehicle diagnosis, measure‐

ment and information system - VAS- and
selecting function (ABS system BOSCH
8.0)
The self-diagnosis of the ABS system BOSCH 8.0 can be per‐
formed using the vehicle diagnosis, measurement and informa‐
tion system - VAS- .
Special tools and workshop equipment required
♦ Vehicle diagnosis, measurement and information system -
VAS-

WARNING

♦ For test drives, the test and measuring equipment must

always be fastened to the rear seat.
♦ The equipment must be operated by an assistant during
test drives.

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

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

 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Mount the plug of the diagnostic cable - VAS- in the vehicle

diagnostic connection (left in the fuse carrier).
– Switch on vehicle diagnosis, measurement and information
system - VAS- .
The vehicle diagnosis, measurement and information system -
VAS- is operational, if it shows the keyboards for the operating
modes.
– Switch on ignition.
– Select “Targeted fault finding” ⇒ Vehicle diagnostic tester on
the screen.

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

2. Perform self-diagnosis - ABS BOSCH 8.0 21

 Roomster 2006 ➤
Brake systems - Edition 02.2014

3 Basic setting of the ABS system

⇒ “3.1 Basic setting - ABS BOSCH 8.0”, page 22
⇒ “3.2 Basic setting - ABS BOSCH 8.2”, page 22
⇒ “3.3 Basic setting - ABS/TCS/ESP BOSCH 8.2i”, page 22
⇒ “3.4 Null balance of the steering angle sender G85 (vehicles
with ABS/TCS/ESP BOSCH 8.0 and ABS/TCS/ESP BOSCH
8.2i)”, page 22
⇒ “3.5 Performing ESP road and system test (vehicles with ABS/
TCS/ESP BOSCH 8.0)”, page 23

3.1 Basic setting - ABS BOSCH 8.0

The function “basic setting” performs the following tasks:
♦ On vehicles with ABS/TCS/ESP BOSCH 8.0 the bleeding of
the hydraulic unit is performed via display group 010 ⇒ Vehicle
diagnostic tester
♦ On vehicles with ABS/TCS/ESP BOSCH 8.0 the null balance
of the steering angle sender - G85- is performed via display
group 001 ⇒ Vehicle diagnostic tester
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ On vehicles with ABS/TCS/ESP BOSCH
unless authorised8.0 the ESP
by ŠKODA AUTO road and AUTO A. S. does not guarantee or accept any liability
A. S. ŠKODA
system test is activated via thewith
display group
respect to 003 ⇒ofVehicle
the correctness information in this document. Copyright by ŠKODA AUTO A. S.�
diagnostic tester
– Bleeding the hydraulic unit (vehicles with ABS/TCS/ESP
BOSCH 8.0) ⇒ page 198 .
– Null balance of the steering angle sender - G85- (vehicles with
ABS/TCS/ESP BOSCH 8.0) ⇒ page 22 .
– Perform road and system test (vehicles with ABS/TCS/ESP
BOSCH 8.0) ⇒ page 23 .

3.2 Basic setting - ABS BOSCH 8.2

Basic setting - ABS BOSCH 8.2 is performed ⇒ Vehicle diagnostic
tester.

3.3 Basic setting - ABS/TCS/ESP BOSCH

8.2i
Basic setting - ABS/TCS/ESP BOSCH 8.2i is performed ⇒ Vehicle
diagnostic tester.
Null balance of the steering angle sender - G85- ⇒ page 22 .

3.4 Null balance of the steering angle send‐

er - G85- (vehicles with ABS/TCS/ESP
BOSCH 8.0 and ABS/TCS/ESP BOSCH
8.2i)
Null balance of the steering angle sender - G85- is required if:
♦ the ABS control unit - J104- or the steering angel sender - G85-
was replaced and the control unit was coded subsequently.
♦ the steering column was replaced
♦ settings have been changed on the chassis within the scope
of an axle alignment.
♦ If as a result of a fault entry in the fault memory of the ABS
control unit - J104- the fault table indicates a fault, perform null
balance.

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

 Roomster 2006 ➤
Brake systems - Edition 02.2014

The null balance of the steering angle sender - G85- is performed

⇒ Vehicle diagnostic tester.

3.5 Performing ESP road and system test

(vehicles with ABS/TCS/ESP BOSCH
8.0)
The ESP road test is a plausibility test of the signals from the
lateral acceleration sender - G200- , yaw rate sender - G202-
(both senders are integrated in the ESP sensor unit - G419- ) and
from the brake pressure sender - G201- (in the hydraulic control
unit).
The ESP road test should be performed after each replacement
of the electrical components of the ESP system.
If the ESP road test is initiated, it can no longer be interrupted and
must be performed.
Perform basic setting of vehicle diagnosis, measurement and in‐
formation system - VAS- ⇒ page 20 .
– Disconnect vehicle diagnosis, measurement and information
system - VAS- .
– Start engine.
– Depress the brake pedal forcefully until the ESP and TCS
warning light - K155- goes out, at the same time the ABS
warning light - K47- lights up.
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– Now carry out the unless
ESPauthorised
road test.
by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

WARNING

♦ The rules of the road traffic regulations must always be

given priority.

– Drive a right or a left curve. Subsequently carry out a change

of direction and drive a left or a right curve.
– After cornering, drive straight ahead for a certain period of
time.

Note

♦ A curve with a radius of 10 to 12 meters and a speed of 15 to

20 km/h must be driven in approx 4 seconds during cornering.
♦ It must be driven in such a way, that no ABS, EDL, TCS or
ESP control is activated.
♦ If there are other traffic dependent driving manoeuvres be‐
tween cornerings, they will have no influence on the ESP road
test.

If the ABS warning light - K47- goes out, the ESP road and system
test was successfully performed and ended; the system is OK.
If the ABS warning light - K47- does not go out, the ESP road and
system test was not successfully performed.
– Repeat ESP road and system test ⇒ page 23 .
If the ABS warning light - K47 - and the ESP and TCS warning
light - K155 - light up, there are faults in the system.
– Interrogating fault memory.

3. Basic setting of the ABS system 23

 Roomster 2006 ➤
Brake systems - Edition 02.2014

4 Electric/electronic components and

fitting locations ABS/ESP
⇒ “4.1 Overview - electric/electronic components and fitting loca‐
tions ABS/ESP BOSCH 8.0 ”, page 24
⇒ “4.2 Electric/electronic components and fitting locations ABS/
ESP BOSCH 8.0”, page 27
⇒ “4.3 Electric/electronic components and fitting locations ABS/
EDL/TCS/ESP BOSCH 8.2i”, page 28

4.1 Overview - electric/electronic compo‐

nents and fitting locations ABS/ESP
BOSCH 8.0

Caution

The hydraulic control unit ABS/TCS/ESP BOSCH 8.0 must not

be disassembled and repaired. In the event of faults or defects,
replace the complete hydraulic control unit.

All components marked with 1) can be tested using the Vehicle

diagnosis, measuring and information system - VAS- .

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

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

 Roomster 2006 ➤
Brake systems - Edition 02.2014

1 - Hydraulic control unit ESP

BOSCH 8.0 1)
❑ ABS/TCS/ESP
❑ Assignment ⇒ Electron‐
ic Catalogue of Original
Parts
❑ Distinguishing features
⇒ page 18
❑ Fitting location
⇒ page 18
❑ removing and installing
⇒ page 37
❑ ABS/TCS/ESP BOSCH
8.0 must not be disas‐
sembled and repaired
2 - Hydraulic control unit ABS
BOSCH 8.01)
❑ different versions:
♦ ABS
♦ ABS/TCS
❑ Assignment ⇒ Electron‐
ic Catalogue of Original
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Parts with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ Distinguishing features
⇒ page 18
❑ Fitting location
⇒ page 18
❑ removing and installing
⇒ page 37
3 - Traction control system
switch - E132- or TCS and ESP
button - E256- 1)
❑ Fitting location: in the
left centre dash panel next to the heater control
❑ Operation: Switching off the TCS or ESP function
❑ removing and installing ⇒ Electrical System; Rep. gr. 96
4 - Brake pad warning light - K32-
❑ function ⇒ page 30
5 - ABS warning light - K47-
❑ function ⇒ page 30
6 - Dual circuit and hand brake system warning light - K7-
❑ function ⇒ page 30
7 - Traction control system warning light - K86- or ESP and TCS warning light - K155-
❑ function ⇒ page 30
8 - Warning light for tyre pressure display - K220-
❑ function ⇒ page 30
9 - Steering angle sender - G85- 1)
❑ only on vehicles with ESP
❑ Fitting location: on the steering column between the steering wheel and steering column switch.
❑ removing and installing ⇒ Electrical System; Rep. gr. 94 .
10 - Diagnostic connection
❑ Fitting location: left in the fuse holder

4. Electric/electronic components and fitting locations ABS/ESP 25

 Roomster 2006 ➤
Brake systems - Edition 02.2014

11 - Rear right and rear left wheel speed sensors -G44/G46- 1)

❑ removing and installing (disc brake and drum brake) ⇒ page 54
❑ can be checked in the function “Targeted fault finding” at the vehicle diagnosis, measurement and in‐
formation system - VAS-
12 - Wheel hub with wheel bearing
❑ removing and installing - disc brake ⇒ Axles, steering; Rep. gr. 42
❑ removing and installing - drum brake ⇒ Axles, steering; Rep. gr. 42
❑ Sensor ring for ABS is built into the wheel hub
13 - Handbrake warning switch - F9- 1)
❑ Fitting location: at the handbrake cable ⇒ page 138
14 - ESP sensor unit - G419- 1)
❑ only on vehicles with ESP
❑ Fitting location: under the left front seat
❑ removing and installing ⇒ page 66
❑ Lateral acceleration sender - G200- and yaw rate sender - G202- are combined in a common housing
with the ESP sensor unit - G419-
15 - Brake light switch - F- 1) and brake pedal switch - F47- 1)
❑ setting, removing and installing ⇒ page 146
16 - Wheel hub with wheel bearing
❑ removing and installing ⇒ Axles, steering; Rep. gr. 40
❑ Sensor ring for ABS is built into the wheel hub
17 - Front right and front left wheel speed sensors -G45/G47- 1)
❑ removing and installing ⇒ page 54
18 - Brake servo unit with master brake cylinder and brake fluid reservoir
❑ removing and installing ⇒ page 173

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

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

 Roomster 2006 ➤
Brake systems - Edition 02.2014

4.2 Electric/electronic components and fitting locations ABS/ESP BOSCH 8.0

1 - ABS control unit - J104-

❑ Fitting location
⇒ page 18
❑ do not disconnect the
plug connection before
the self-diagnosis is
complete; switch off the
ignition before discon‐
necting the plug con‐
nection
❑ removing and installing
⇒ page 37
2 - ABS hydraulic unit - N55-
The hydraulic unit consists of
these components:
❑ ABS return flow pump -
V39-
❑ Valve block (containing
the inlet and outlet
valves)
❑ The ABS return flow
pump - V39- and the
valve block must not be
separated from each
other
❑ removing and installing
⇒ page 37
3 - ABS warning light - K47-
❑ Fitting location: in the
dash panel insert
function ⇒ page 30

4 - Dual circuit andProtected

hand brakeby copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
system warning light - K7
unless -
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ Fitting location: in the
dash panel insert
function ⇒ page 30

5 - Warning light for tyre pressure display - K220-

❑ Fitting location: in the dash panel insert
function ⇒ page 30

6 - Diagnostic connection
❑ Fitting location: left in the fuse holder
7 - Brake light switch - F-
❑ Including brake pedal switch - F47-
❑ removing and installing ⇒ page 178
8 - Front right/left wheel speed sensors -G45- / -G47-
❑ removing and installing ⇒ page 54
9 - Wheel hub with wheel bearing
❑ the sensor ring for ABS is installed at the wheel bearing

4. Electric/electronic components and fitting locations ABS/ESP 27

 Roomster 2006 ➤
Brake systems - Edition 02.2014

10 - Rear right/left wheel speed sensors -G44- / -G46-

❑ removing and installing ⇒ page 54
11 - Wheel hub with wheel bearing
❑ the sensor ring for ABS is installed at the wheel bearing

4.3 Electric/electronic components and fitting locations ABS/EDL/TCS/ESP

BOSCH 8.2i

1 - ABS control unit - J104-

❑ Fitting location
⇒ page 18
❑ do not disconnect the
plug connection before
the self-diagnosis is
complete; switch off the
ignition before discon‐
necting the plug con‐
nection
The following components are
integrated in the control unit:
♦ Lateral acceleration sender
- G200-
♦ Yaw rate sender - G202-
♦ Longitudinal acceleration
sender - G251- (depending
on equipment)
❑ removing and installing
⇒ page 80
2 - ABS hydraulic unit - N55-
The hydraulic unit consists of
these components:
❑ ABS return flow pump -
V39-
❑ Brake pressure sender
1 - G201-
❑ Valve block (containing
the inlet and outlet
valves)
❑ The ABS return flow
pump - V39- and the
valve block must not be
separated from each
other
❑ removing and installing ⇒ page 80
3 - Warning light 2 for ESP and TCS - K216-
❑ Fitting location: in the dash panel insert
4 - ABS warning light - K47-
❑ Fitting location: in the dash panel insert
function ⇒ page 34
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
5 - ESP and TCS warning light - K155- unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ Fitting location: in the dash panel insert
function ⇒ page 34

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

 Roomster 2006 ➤
Brake systems - Edition 02.2014

6 - Dual circuit and hand brake system warning light - K7-

❑ Fitting location: in the dash panel insert
function ⇒ page 34

7 - Warning light for tyre pressure display - K220-

❑ Fitting location: in the dash panel insert
function ⇒ page 34

8 - Brake light switch - F-

❑ Including brake pedal switch - F47-
❑ removing and installing ⇒ page 178
9 - TCS and ESP button - E256-
❑ Fitting location: In the dash panel
10 - Diagnostic connection
❑ Fitting location: left in the fuse holder
11 - Steering angle sender - G85-
❑ Fitting location: on the steering column between the steering wheel and steering column switch.
❑ removing and installing ⇒ Electrical System; Rep. gr. 94
12 - Front right/left wheel speed sensors -G45- / -G47-
❑ removing and installing ⇒ page 54
13 - Wheel hub with wheel bearing
❑ the sensor ring for ABS is installed at the wheel bearing
14 - Rear right/left wheel speed sensors -G44- / -G46-
❑ removing and installing ⇒ page 54 by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
15 - Wheel hub with wheel bearing
❑ the sensor ring for ABS is installed at the wheel bearing

4. Electric/electronic components and fitting locations ABS/ESP 29

 Roomster 2006 ➤
Brake systems - Edition 02.2014

5 Indication of faults by means of warn‐

ing lights
⇒ “5.1 ABS/TCS/ESP BOSCH 8.0”, page 30
⇒ “5.2 ABS BOSCH 8.2/8.2i”, page 34

5.1 ABS/TCS/ESP BOSCH 8.0

Special tools and workshop equipment required
♦ Vehicle diagnosis, measurement and information system -
VAS-

Note

When using the vehicle diagnosis, measurement and information

system - VAS- the electrical test is integrated in the “Targeted fault
finding”.

Dash panel insert

Different versions of the dash panel insert according to the vehicle
equipment ⇒ electronic catalogue of original parts
Warning lights
Pos. Denomination
1 Dual circuit and hand brake system warning light - K7-
2 Traction control system warning light - K86-
ESP and TCS warning light - K155-
3 Brake pad warning light - K32-
4 ABS warning light - K47-
5 Warning light for tyre pressure display - K220-
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Brake pad warning light - K32- (-3-)
♦ If the brake pad warning light - K32- (-3-) does not go out after
switching the ignition on or glows during the driving operation,
the following can be the causes of the fault:
a - the brake pads could be worn down.
– Check the brake pads on the front and rear axles. The brake
pads must be replaced, if they are worn out ⇒ page 92
b - there is a fault in the wiring ⇒ Current flow diagrams, Electrical
fault finding and Fitting locations

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

 Roomster 2006 ➤
Brake systems - Edition 02.2014

ABS warning light - K47- (-4-)

♦ If the ABS warning light - K47- (-4-) does not go out after the
ignition is switched on and after completion of the test se‐
quence, the causes of the fault may be as follows:
a - the supply voltage is less than 11 V.
b - an ABS fault is present.

WARNING

If an ABS fault -b- is present, the anti-lock brake system re‐

mains switched off while the conventional brake system re‐
mains fully operational.

c - a sporadic fault exists on a wheel speed sensor after the last

vehicle start (sporadic fault).
In this case of the fault on the wheel speed sensor the ABS warn‐
ing light - K47- goes out automatically after restarting the vehicle
and after a speed above 20 km/h is reached.
d - the connection from the dash panel insert to the ABS control
unit - J104- (data bus) is interrupted ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations
e - The dash panel insert is defective.
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unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
ABSwith
warning
respect to light - K47-of(-4-)
the correctness andindual
information circuitCopyright
this document. and hand brake
by ŠKODA AUTO A. S.�
system warning light - K7- (-1-)
♦ If the ABS warning light - K47- (-4-) goes out or the dual circuit
and hand brake system warning light - K7- (-1-) lights up or
flashes, the causes of the fault may be:
a - the hand-brake is still applied (warning light lights up).
b - the brake fluid level is too low (warning light flashes).
c - there is a fault in the wiring between dash panel insert and
brake fluid level warning contact - F34- ⇒ Current flow diagrams,
Electrical fault finding and Fitting locations.
♦ If the ABS warning light - K47- (-4-), and the dual circuit and
hand brake system warning light - K7- (-1-) lights up, this
means the anti-blocking system and EBD (Electronic Brake
pressure Distribution) system is faulty.
One must reckon with a somewhat changed braking characteris‐
tic.

WARNING

Once the ABS warning light - K47- and the dual circuit and
hand brake system warning light - K7- have lit up then one can
expect the rear wheels to lock quite early on when braking.

5. Indication of faults by means of warning lights 31

 Roomster 2006 ➤
Brake systems - Edition 02.2014

ABS warning light - K47- (-4-), dual circuit and hand brake system
warning light - K7- (-1-), traction control system warning light -
K86- (-2-) and ESP and TCS warning light - K155- (-2-)
♦ If the ABS warning light - K47- (-4-) and the dual circuit and
hand brake system warning light - K7- (-1-) go out, but the
traction control system warning light - K86- (-2-) or the ESP
and TCS warning light - K155- (-2-) remain lit, the causes of
the fault may be:
a - Fault relates only to TCS or ESP.
b - ASR is switched off with traction control system switch - E132-
or with TCS and ESP button - E256- .
c - TCS or ESP is in regulating mode (flashing rhythm 3x per sec‐
ond).
d - Short-circuit to positive in traction control system switch -
E132- or in TCS and ESP switch - E256- (warning light goes out
after approx. 5 minutes).

Warning light for tyre pressure display -K220- (-5-)

♦ Warning light for tyre pressure inspection display - K220-
(-5-) comes on:
– Carry out tyre pressure inspection.
– Correct the nominal pressure of the tyre.
– Perform basic setting.
Initiating basic setting:
• Ignition on

– Press the button for tyre pressure inspection - E226- -arrow-

for more than 2 seconds.
The button is located in the left centre console of the hand-brake
lever.
When the button for tyre pressure inspection - E226- is pressed
the warning light for tyre pressure inspection display - K220- lights
up in the dash panel insert.
The basic setting is confirmed with an acoustic signal.
– Switch off ignition.
– After the ignition is switched on again, the warning light for tyre
pressure inspection display - K220- does no longer light up.
♦ Warning light for tyre pressure inspection display - K220-
flashes:
– Carry out tyre pressure inspection.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Correctunless
the nominal
authorised bypressure
ŠKODA AUTO ofA.the tyre.AUTO A. S. does not guarantee or accept any liability
S. ŠKODA
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
• Ignition on

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

 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Press the buttons for tyre pressure inspection - E226-

-arrow- and Buttons for ASR and ESP - E256- or the traction
control system switch - E132- at the same time for more than
2 seconds ((fitting location of the button: in the left centre dash
panel next to the heater control)).
If the warning light for tyre pressure inspection display - K220-
continues to flash:
– Carry out “Targeted fault finding” with vehicle diagnosis,
measurement and information system - VAS- ⇒ page 20 .

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

5. Indication of faults by means of warning lights 33

 Roomster 2006 ➤
Brake systems - Edition 02.2014

5.2 ABS BOSCH 8.2/8.2i

Dash panel insert
Different versions of the dash panel insert according to the vehicle
equipment ⇒ electronic catalogue of original parts
Warning lights
Pos. Denomination
1 Warning light 2 for ESP and TCS - K216-
2 ABS warning light - K47-
3 ESP and TCS warning light - K155-
4 Dual circuit and hand brake system warning light - K7-
5 Warning light for tyre pressure display - K220-
Warning light 2 for ESP and TCS - K216-
If the traction control system is switched off in the centre console
using the TCS and ESP button - E256- , the warning light 2 for
ESP and TCS - K216- -1- must light up when the ignition is
switched on.
♦ If the warning light 2 for ESP and TCS - K216- -1- does not
light up when the traction control system is switched off in the
centre console using the TCS and ESP button - E256- and the
ignition is switched on, this may be due to the following cause:
-a- the connection of the dash panel insert to the ABS control unit
- J104- is interrupted ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations

Note

♦ Only the traction control system can be switched off using the
button for TCS and ESP - E256- .
♦ The ESP system cannot be switched off, i.e. the ESP system
always remains active.

ABS warning light - K47-

♦ If the ABS warning light - K47- -2- does not go out after switch‐
ing on the ignition and the completion of the test, this may be
due to the following causes:
-a- the supply voltage is less than 10 V
-b- an ABS fault is present
If an ABS fault -b- is present, the anti-lock brake system remains
switched off while the conventional brake system remains fully
operational.
-c- a sporadic fault existed on a wheel speed sensor after the last
vehicle start
In case of a wheel speed sensor fault -c-, the ABS warning light
- K47- goes out automatically after restarting the engine and after
a speed above 2.75 km/h is reached.
-d- the connection of the dash panel insert to the ABS control unit
- J104- is interrupted ⇒ Current flow diagrams, Electrical fault
finding and Fitting locations
ABS warning light - K47- and dual circuit and hand brake system
warning light - K7- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

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

 Roomster 2006 ➤
Brake systems - Edition 02.2014

♦ If the ABS warning light - K47- -2- goes out, however the dual
circuit and hand brake system warning light - K7- -4- remains
lit up, this may be due to the following causes:
-a- the hand-brake is applied
-b- the brake fluid level is too low
-c- Voltage supply for the dual circuit and hand brake system
warning light - K7- ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations
♦ If the ABS warning light - K47- (-2-), and the dual circuit and
hand brake system warning light - K7- (-4-) light up, this means
the anti-blocking system and EBD (Electronic Brake pressure
Distribution) system has a fault.

Caution

Once the ABS warning light - K47- and the dual circuit and
hand brake system warning light - K7- have lit up then the rear
wheels lock quite early on when braking.

ESP and TCS warning light - K155-

only on vehicles with ESP

♦ If the ESP and TCS warning light - K155- -3- does not go out
after switching on the ignition and the completion of the test,
this may be due to the following causes:
-a- short circuit to positive in TCS and ESP button - E256-
-b- voltage supply for the ESP and TCS warning light - K155- de‐
fective ⇒ Current flow diagrams, Electrical fault finding and Fitting
locations
-c- the traction control system/ESP system was switched off using
the TCS and ESP button - E256-
There is a fault which exclusively effects the TCS/ESP safety
system. The ABS/EDL as well as EBD safety systems of the ve‐
hicle remain fully functional ⇒ Interrogate fault memory ⇒ Vehicle
diagnostic tester.
If the warning light for ESP and TCS - K155- flashes while driving,
the traction control system or the ESP system is operating in reg‐
ulating mode.

Warning light for tyre pressure display -K220- (-5-)

♦ Warning light for tyre pressure inspection display - K220-
(-5-) comes on:
– Carry out tyre pressure inspection.
– Correct the nominal pressure of the tyre.
– Perform basic setting.
Initiating basic setting:
• Ignition on Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

5. Indication of faults by means of warning lights 35

 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Press the button for tyre pressure inspection - E226- -arrow-

for more than 2 seconds.
The button is located in the left centre console of the hand-brake
lever.
When the button for tyre pressure inspection - E226- is pressed
the warning light for tyre pressure inspection display - K220- lights
up in the dash panel insert.
The basic setting is confirmed with an acoustic signal.
– Switch off ignition.
– After the ignition is switched on again, the warning light for tyre
pressure inspection display - K220- does no longer light up.
♦ Warning light for tyre pressure inspection display - K220-
flashes:
– Carry out tyre pressure inspection.
– Correct the nominal pressure of the tyre.
• Ignition on

– Press the buttons for tyre pressure inspection - E226-

-arrow- and Buttons for ASR and ESP - E256- or the traction
control system switch - E132- at the same time for more than
2 seconds ((fitting location of the button: in the left centre dash
panel next to the heater control)).
If the warning light for tyre pressure inspection display - K220-
continues to flash:
– Carry out “Targeted fault finding” with vehicle diagnosis,
measurement and information system - VAS- ⇒ Vehicle diag‐
nostic tester. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

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

 Roomster 2006 ➤
Brake systems - Edition 02.2014

6 Hydraulic control unit (ABS systems

BOSCH 8.0), brake servo unit/master
brake cylinder
⇒ “6.1 Summary of components of control unit, brake servo unit
and master brake cylinder”, page 37
⇒ “6.2 Removing and installing hydraulic control unit ABS BOSCH
8.0 - left-hand drive”, page 40
⇒ “6.3 Removing and installing hydraulic control unit ABS BOSCH
8.0 - vehicles - right-hand drive”, page 44
⇒ “6.4 Removing and installing the ABS control unit bracket
BOSCH 8.0”, page 48
⇒ “6.5 Connect the brake lines”, page 52

6.1 Summary of components of control unit, brake servo unit and master brake
cylinder

Note

♦ Mount braket before installing the lines.

♦ Do not bend brake lines when assembling or when connecting.
♦ Install brake hoses without transposition.
♦ Brake hoses must not come into contact with other components during operating condition.
♦ Do not remove the plugs on the connection threads and the holes in the parts carrying brake fluid until just
before assembling.
♦ Tighten all the pipe screws of the lines to a tightening torque of 14 Nm.
♦ The repair of the hydraulic control units ABS/TCS/ESP BOSCH 8.0 is not permissible.

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

6. Hydraulic control unit (ABS systems BOSCH 8.0), brake servo unit/master brake cylinder 37
 Roomster 2006 ➤
Brake systems - Edition 02.2014

1 - Hydraulic control unit

❑ ABS BOSCH 8.0
❑ Removing and installing
- left-hand drive vehicle
⇒ page 40
❑ Removing and installing
- right-hand drive vehi‐
cle ⇒ page 44
❑ ABS/TCS BOSCH 8.0
❑ Assignment ⇒ Electron‐
ic Catalogue of Original
Parts
❑ Marking on the “ABS”
unit
2 - Brake line
❑ Marking on the unit “FR”
❑ to front right brake cali‐
per
❑ Connect ⇒ page 52
3 - Brake line
❑ Marking on the unit “RL”
❑ to wheel brake cylinder/
rear left brake caliper
❑ Connect ⇒ page 52
4 - Brake line
❑ Marking on the unit “RR”
❑ to wheel brake cylinder/
rear right brake caliper
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ Connect ⇒ page
unless authorised 52 AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
by ŠKODA
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
5 - Brake line
❑ Marking on the unit “FL”
❑ to front left brake caliper
❑ Connect ⇒ page 52
6 - Hydraulic control unit
❑ ABS/TCS/ESP BOSCH 8.0
❑ Removing and installing - left-hand drive vehicle ⇒ page 40
❑ Removing and installing - right-hand drive vehicle ⇒ page 44
❑ Assignment ⇒ Electronic Catalogue of Original Parts
❑ Marking on the “ESP” unit
7 - Brake line
❑ Marking on the unit “HZ2”
❑ Master brake cylinder/floating piston circuit to control unit
❑ Connect ⇒ page 52
8 - Brake line
❑ Marking on the unit “HZ1”
❑ Master brake cylinder/push rod piston circuit to control unit
❑ Connect ⇒ page 52
9 - Support
❑ for hydraulic control unit ABS/TCS/ESP BOSCH 8.0
❑ removing and installing ⇒ page 48

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

 Roomster 2006 ➤
Brake systems - Edition 02.2014

10 - Screws, 8 Nm
❑ for bracket to control unit
11 - Line holder
❑ for brake line
❑ Assignment ⇒ Electronic Catalogue of Original Parts
12 - Support
❑ for brake line
❑ 2 units
❑ Assignment ⇒ Electronic Catalogue of Original Parts
13 - Support
❑ for brake line
❑ 3 units
❑ Assignment ⇒ Electronic Catalogue of Original Parts
14 - Brake servo unit
❑ check ⇒ page 173
❑ removing and installing ⇒ page 173
15 - Master brake cylinder
❑ cannot be repaired, replace completely in the event of faults
❑ test tightness ⇒ page 179
❑ removing and installing ⇒ page 173
16 - Brake fluid reservoir
17 - Self-locking nut, 20 Nm
❑ replace after each removal
❑ for bracket to body
18 - Support
❑ for ABS, ABS/TCS, ABS/TCS/ESP BOSCH 8.0
❑ removing and installing ⇒ page 48
19 - Hexagon collar nut, 20 Nm
❑ replace after each removal
❑ for bracket to body
20 - Support
❑ for hydraulic control unit ABS, ABS/TCS BOSCH 8.0
❑ removing and installing ⇒ page 48
21 - Support
❑ for brake line
❑ 2 units
❑ Assignment ⇒ Electronic Catalogue of Original Parts

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

6. Hydraulic control unit (ABS systems BOSCH 8.0), brake servo unit/master brake cylinder 39
 Roomster 2006 ➤
Brake systems - Edition 02.2014

6.2 Removing and installing hydraulic con‐

trol unit ABS BOSCH 8.0 - left-hand
drive

WARNING

♦ Make sure that no brake fluid gets into the plug connector
housing of the control unit. This may result in the corrosion
of the contacts and thus to system failure.
♦ Carefully clean out the plug connector housing with com‐
pressed air if it gets dirty.
♦ Do not bend the brake lines around the control unit.

Special tools and workshop equipment required

♦ Brake pedal load , e.g. -V.A.G 1869/2-
♦ Vehicle diagnosis, measurement and information system -
VAS-
♦ Brake filling and bleeding device , e. g. -VAS 5234-
♦ Bleeding bottle (commercially available)
♦ Repair kit part number 1H0 698 311 A
♦ Brake fluid ⇒ page 13
Removing:
– Disconnect battery ⇒ Electrical System; Rep. gr. 27
– Remove engine cover ⇒ engine; Rep. gr. 10 .
Vehicles with TDI PD Turbocharger engines
– Remove top charge-air pipe -1- with connecting hose -2- ⇒
TDI Engine; Rep. gr. 21 .
Continued for all vehicles

– Actuate brake pedal and lock in place with brake pedal load.
– Attach the bleeder hose of the bleeding bottle onto the vent
valve of the front left brake
Protected caliper
by copyright. and
Copying open
for private bleeder purposes,
or commercial valve. in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Shut the vent valve oncetothe
with respect brake fluid
the correctness has flown
of information out. Copyright by ŠKODA AUTO A. S.�
in this document.

– Disconnect the bleeder hose from the vent valve.

– Place sufficient non-fluffing cloths under and around the hy‐
draulic control unit.
Unlock the multi-pin plug connection
The unlocking of the multi-pin plug connection is described ac‐
cording to the example for the ABS BOSCH 8.0. On the ABS/TCS
and ABS/TCS/ESP systems BOSCH 8.0 the unlatching is identi‐
cal.

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

 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Unlock the multi-pin plug connection -1-.

– Insert red fuse -2- up to the stop in -direction of the arrow-.

– Swivel the clamp downwards -1- up to the stop in the

-direction of arrow-.
– Disconnect multi-pin plug connection -2- from ABS control unit
- J104- .
– Close the plug connector housing of the ABS control unit -
J104- with a cap.
Unscrew the brake lines from the control unit.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
ABS, ABS/TCS BOSCH 8.0
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– If necessary remove the brake lines from the line holder.

– Mark brake lines -1...6-.
– Unscrew the brake lines -1...6- from the control unit.
– Close off immediately brake lines.
– Shut off threaded bores (brake line connections) on the control
unit with plugs from repair kit part number 1H0 698 311 A.

ABS/TCS/ESP BOSCH 8.0

– If necessary remove the brake lines from the line holder.
– Mark brake lines -1...6-.
– Unscrew the brake lines -1...6- from the control unit.
– Close off immediately brake lines.
– Shut off threaded bores (brake line connections) on the control
unit with plugs from repair kit part number 1H0 698 311 A.
Remove the hydraulic control unit
The removal of the control unit is described on an ABS/TCS/ESP
unit. The removal of an ABS or an ABS/TCS unit occurs in the
same way as for the ABS/TCS/ESP unit.

6. Hydraulic control unit (ABS systems BOSCH 8.0), brake servo unit/master brake cylinder 41
 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Unscrew nuts -4- from bracket -3-.

– Unscrew nut -6-.
– Remove the hydraulic control unit ABS, ABS/TCS or ABS/
TCS/ESP BOSCH 8.0 -1- with bracket -2- and -3- upwards out
of the vehicle.
5 - Threaded bores welded to the body
7 - Threaded bores welded to the body
Installing:

Note

♦ New control units are filled with brake fluid and are pre-bled.
♦ Only then remove screw plugs from the unit when the relevant
line is installed.
♦ If the plugs were already removed from the unit, then brake
fluid may escape and adequate filling and bleeding can no
longer be guaranteed.

Installation is performed in the reverse order, pay attention to the

following points:

WARNING

Pay attention to the correct channel assignment of the lines.

Interchanging the lines will result in dangerous brake control
actions.

– Connect the brake lines ⇒ page 52

– Make sure that the multi-pin plug connection latches correctly
with the ABS control unit - J104- .
– Remove the brake pedal load , e.g. -V.A.G 1869/2- .
– Bleeding Brake System ⇒ page 198
– Code ABS control unit - J104- using the vehicle diagnosis,
measurement and information system - VAS- ⇒ page 20 .
– Perform test drive after the bleeding of air with at least one
ABS adjustment.

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

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

 Roomster 2006 ➤
Brake systems - Edition 02.2014

Tightening torques:
Brake line to hydraulic control unit 14 Nm
Bracket with hexagon collar nut to body 20 Nm
♦ Use new nut!

Bracket with nuts to body 20 Nm

♦ Use new nuts!

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

43
 Roomster 2006 ➤
Brake systems - Edition 02.2014

6.3 Removing and installing hydraulic con‐

trol unit ABS BOSCH 8.0 - vehicles -
right-hand drive
Special tools and workshop equipment required
♦ Brake pedal load , e.g. -V.A.G 1869/2-
♦ Vehicle diagnosis, measurement and information system -
VAS-
♦ Brake filling and bleeding device , e. g. -VAS 5234-
♦ Bleeding bottle (commercially available)
♦ Repair kit part number 1H0 698 311 A
♦ Brake fluid ⇒ page 13
Fitting position:
The control unit is bolted to the hydraulic unit and is located on
the left in the engine compartment -2-.

WARNING

♦ Make sure that no brake fluid gets into the plug connector
housing of the control unit. This may result in the corrosion
of the contacts and thus to system failure.
♦ Carefully clean out the plug connector housing with com‐
pressed air if it gets dirty.
♦ Do not bend the brake lines around the control unit.

Removing:
– Disconnect battery ⇒ Electrical System; Rep. gr. 27
– Remove engine cover ⇒ engine; Rep. gr. 10 .
– Remove air filter ⇒ Engine; Rep. gr. 24 (fuel engines) or ⇒
Engine; Rep. gr. 23 (diesel engines).
– Remove battery and battery tray ⇒ Electrical System; Rep.
gr. 27 .

– Actuate brake pedal and lock in place with brake pedal load.
– Attach the bleeder hose of the bleeding bottle onto the vent
valve of the front left brake caliper and open bleeder valve.
– Shut the vent valve once the brake fluid has flown out.
– Disconnect the bleeder hose from the vent valve.
– Place sufficient non-fluffing cloths under and around the hy‐
draulic control unit.
Unlock the multi-pin plug connection
The unlocking of the multi-pin plug connection is described ac‐
cording to the example for the ABS BOSCH 8.0. On the ABS/TCS
and ABS/TCS/ESP systems BOSCH 8.0 the unlatching is identi‐
cal.

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

44
 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Unlock the multi-pin plug connection -1-.

– Insert red fuse -2- up to the stop in -direction of the arrow-.

– Swivel the clamp downwards -1- up to the stop in the

-direction of arrow-.
– Disconnect multi-pin plug connection -2- from the ABS control
unit - J104- .
– Close the plug connector housing of the ABS control unit -
J104- with a cap.
Unscrew the brake lines from the control unit.

ABS, ABS/TCS BOSCH 8.0

– If necessary remove the brake lines from the line holder.
– Mark brake lines -1...6-.
– Unscrew the brake lines -1...6- from the control unit.
– Close off immediately brake lines.
– Shut off threaded bores (brake line connections) on the control
unit with plugs from repair kit part number 1H0 698 311 A.

ABS/TCS/ESP BOSCH 8.0

– If necessary remove the brake lines from the line holder.
– Mark unless
brake lines -1...6-.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Unscrew the brake lines -1...6- from the control unit.
– Close off immediately brake lines.
– Shut off threaded bores (brake line connections) on the control
unit with plugs from repair kit part number 1H0 698 311 A.
Remove the hydraulic control unit
The removal of the control unit is described on an ABS/TCS/ESP
unit. The removal of an ABS or an ABS/TCS unit occurs in the
same way as for the ABS/TCS/ESP unit.

45
 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Unscrew nuts -4- from bracket -3-.

– Unscrew nut -6-.
– Remove the hydraulic control unit ABS, ABS/TCS or ABS/
TCS/ESP BOSCH 8.0 -1- with bracket -2- and -3- upwards out
of the vehicle.
5 - Threaded bores welded to the body
7 - Threaded bores welded to the body
Installing:

Note

♦ New control units are filled with brake fluid and are pre-bled.
♦ Only then remove screw plugs from the unit when the relevant
line is installed.
♦ If the plugs were already removed from the unit, then brake
fluid may escape and adequate filling and bleeding can no
longer be guaranteed.

Installation is performed in the reverse order, pay attention to the

following points:

WARNING

Pay attention to the correct channel assignment of the lines.

Interchanging the lines will result in dangerous brake control
actions.

– Connect the brake lines ⇒ page 52

– Make sure that the multi-pin plug connection latches correctly
with the ABS control unit - J104- .
– Remove the brake pedal load , e.g. -V.A.G 1869/2- -V.A.G
1869/2- .
– Bleed brake system ⇒ page 198
– Code ABS control unit - J104- using the vehicle diagnosis,
measurement and information system - VAS- ⇒ page 20 .
– Perform test drive after the bleeding of air with at least one
ABS adjustment.

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

46
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Tightening torques:
Brake line to hydraulic control unit 14 Nm
Bracket with hexagon collar nut to body 20 Nm
♦ Use new nut!

Bracket with nuts to body 20 Nm

♦ Use new nuts!

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

47
 Roomster 2006 ➤
Brake systems - Edition 02.2014

6.4 Removing and installing the ABS control

unit bracket BOSCH 8.0
Removing and installing bracket for ABS or ABS/TCS BOSCH 8.0
Removing:
– Removing the hydraulic control unit ABS or ABS/TCS BOSCH
8.0 ⇒ page 40 .
– Separate bracket -4- from the fixing bolt of the bracket -2-.
– Release screws -3- (2x).
– Remove the bracket -2- from the control unit -1-.
Installing:
Installation is carried out in the reverse order.

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

48
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Tightening torque:
Bracket to hydraulic control unit 8 Nm

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

49
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Removing and installing bracket for ABS/TCS/ESP BOSCH 8.0

Removing:
– Removing the hydraulic control unit ABS/TCS/ESP
BOSCH 8.0 ⇒ page 40
– Separate bracket -4- from the fixing bolt of the bracket -2-.
– Release screws -3- (3x).
– Remove the bracket -2- from the control unit -1-.
Installing:
Installation is carried out in the reverse order.

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

50
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Tightening torque:
Bracket to hydraulic control unit 8 Nm

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

51
 Roomster 2006 ➤
Brake systems - Edition 02.2014

6.5 Connect the brake lines

Note

♦ Mount braket before assembling the brake lines.

♦ Do not bend brake lines when assembling or when connecting.
♦ Install brake hoses without transposition.
♦ Brake hoses must not come into contact with other compo‐
nents during operating condition.
♦ Do not remove the plugs on the connection threads and the
holes in the parts carrying brake fluid until just before assem‐
bling.
♦ Tightening torque of pipe screws for brake lines of 14 Nm.

WARNING

Pay attention to the correct channel assignment of the brake

lines. Interchanging the brake lines will result in dangerous
brake control actions.

vehicles with ABS or ABS/TCS BOSCH 8.0

Connect the brake lines to the master brake cylinder
Pos. Denomination Connecting points
1 HZ1 Master brake cylinder/push rod piston
circuit
2 HZ2 Master brake cylinder/floating piston
circuit

Connect the brake lines to the hydraulic control unit

Pos. Denomination Connecting points
1 FR Front right brake caliper
2 RL Rear left wheel-brake cylinder/brake
caliper
3 RR Rear right wheel-brake cylinder/brake
caliper
4 FL Front left brake caliper
5 HZ2 Master brake cylinder/floating piston
circuit
6 HZ1 Master brake cylinder/push rod piston
circuit
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Vehicles with ABS//TCS/ESP BOSCH 8.0
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

52
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Connect the brake lines to the master brake cylinder

Pos. Denomination Connecting points
1 HZ1 Master brake cylinder/push rod piston
circuit
2 HZ2 Master brake cylinder/floating piston
circuit

Note

♦ When tightening the pipe screw, counterhold the brake line in

the area of the crimping -arrow A- by hand.
♦ When tightening the pipe screw, counterhold the brake line in
the area of the crimping -arrow B- by hand.

Connect the brake lines to the hydraulic control unit

Pos. Denomination Connecting points
1 FR Front right brake caliper
2 RL Rear left wheel-brake cylinder/brake
caliper
3 RR Rear right wheel-brake cylinder/brake
caliper
4 FL Front left brake caliper
5 HZ2 Master brake cylinder/floating piston
circuit
6 HZ1 Master brake cylinder/push rod piston
circuit

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

53
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7 Removing and installing parts of the

ABS System on the front and rear
axle
⇒ “7.1 Removing and installing the ABS speed sensor on the front
axle ”, page 54
⇒ “7.2 Removing and installing front wheel speed sensor cables
- Vehicles with ABS BOSCH 8.0”, page 56
⇒ “7.3 Removing and installing the ABS speed sensor on the rear
axle - vehicles up to 11/2012.”, page 60
⇒ “7.4 Removing and installing the ABS speed sensor on the rear
axle - vehicles as of 11/2012.”, page 62
⇒ “7.5 Repairing rear ABS wheel speed sensor cables - Vehicles
with ABS BOSCH 8.0”, page 64

7.1 Removing and installing the ABS speed

sensor on the front axle
Removing:
– Raise vehicle.
– Disconnect plug connection -1- for ABS wheel speed sensor
cable from wheel speed sensor.
– Unscrew Allan screw -3-. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Remove the ABS speed sensor -2- from the wheel-bearing
housing.
Installing:
– Insert speed sensor into the wheel bearing housing and tight‐
en the Allan screw -3-.
– Connect plug connection -1- for wheel speed sensor cable/
ABS speed sensor.

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Tightening torque:
Speed sensor to wheel-bearing housing 8 Nm

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

55
 Roomster 2006 ➤
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7.2 Removing and installing front wheel

speed sensor cables - Vehicles with
ABS BOSCH 8.0
Special tools and workshop equipment required
♦ Wiring loom repair kit , e.g. Škoda Car Tool Kit, Order No.:
S 504 500 V
♦ Vehicle diagnosis, measurement and information system -
VAS-
Removing:

Note

It is prohibited to repair shielded ABS cables.

– Disconnect battery ⇒ Electrical System; Rep. gr. 27 .

– Remove engine cover ⇒ engine; Rep. gr. 10 .
Vehicles with TDI PD Turbocharger engines
– Remove charge-air pipe at the top -1- with connecting hose
-2- ⇒ engine; Rep. gr. 21 .
Continued for all vehicles

– Unlock the multi-pin plug connection -1-.

– Insert red fuse -2- up to the stop in -direction of the arrow-.
2 - Hydraulic control unit

– Swivel the clamp downwards -1- up to the stop in the

-direction of arrow-.
– Disconnect the multi-pin plug connection -2- from the hydraulic
control unit.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

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 Roomster 2006 ➤
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– Open cable straps -2-.

– Lever off the cap -1- of the multi-pin plug connection on both
sides from the catches -arrow- with a screwdriver.
– Remove the cap -1- from the bottom part of the multi-pin plug
connection.

– Slide secondary lock (purple) -1- with a small screwdriver in

the -direction of the arrow-.
At the same time the contacts are released.

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

Contact assignment for multipin plug connector wiring loom - ABS

control unit - J104-
Contact Wiring to component
6 + 18 Front right wheel speed sensor - G45-
22 +34 Front left wheel speed sensor - G47-
19 + 31 Rear right wheel speed sensor - G44-
20 + 33 Speed sensor rear left - G46-
– Open wiring loom.
– Press out the relevant contacts using a suitable ejection tool
from the wiring loom repair kit.
– Raise vehicle.
– Remove wheel.
– Release plug connection on ABS speed sensor and discon‐
nect plug connection.
– Remove defective ABS speed sensor cable.
Installing:
– Draw in new wheel speed sensor cable.
– Connect wheel speed sensor cable to ABS speed sensor.

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– Clip on speed sensor cable -arrows- and mount in bracket

-1-.
– Actuate steering from left to right up to the stop and check for
free movement of the wheel speed sensor cable.

Note

When assembling the wheel speed sensor cable, make sure it is

not twisted when installed in the wheelhouse.

– Install wheel ⇒ Wheels, Tyres; Rep. gr. 44 .

– Lower the vehicle.

– Guide the contact into the plug connector housing and insert
the single cable seal up to the stop using a suitable plug-in tool
from the wiring loom repair kit.
– Secure contacts by sliding the secondary lock (purple).

– Insert catch -arrow A- of the cap -1- into the recess -arrow B-
of the bottom part -2- of the multi-pin plug connection.
– Swivel cover -1- in -direction of arrow- and lock into position
with the bottom part -2- of the multi-pin plug connection.
– Mount new cable strap for wiring loom on multi-pin plug con‐
nection.
– Insert the multi-pin plug connection on the ABS control unit -
J104- and lock.
Vehicles with TDI PD Turbocharger engines

– Install charge-air pipe at the top -1- with connecting hose -2-
⇒ engine; Rep. gr. 21 .
Continued for all vehicles
– Install engine cover ⇒ engine; Rep. gr. 10 .
– Connect battery ⇒ Electrical System; Rep. gr. 27 .
– Perform a vehicle system test using the vehicle diagnosis,
measurement and information system - VAS- ⇒ page 20 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability

58
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Tightening torque:
Wheel bolts 120 Nm

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

59
 Roomster 2006 ➤
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7.3 Removing and installing the ABS speed

sensor on the rear axle - vehicles up to
11/2012.

Note

The procedure for removal and installation of the speed sensor is

identical for vehicles with drum brakes and for vehicles with disc
brakes.

Removing:
– Removing side trim panel of C pillar in luggage compartment
⇒ Body Work; Rep. gr. 70 .
– Disconnect the plug connection -1- at the ABS speed sensor
and undo the line from the brackets -arrow-.
– Release the rubber grommet and pull the wheel speed sensor
cable outwards out of the vehicle.
– Raise vehicle.

– Release Allan screw -arrow-.

– Pull the wheel speed sensor -1- out of the opening in the axle
stud and unclip its cables on the body.

Note

The wheel speed sensor is shown on the vehicle with disc brakes.

Installing:
– Insert
Protectedthe wheel Copying
by copyright. speedforsensor
private or in the bore
commercial of the
purposes, axle
in part or instud
whole,and
is not permitted
tighten the Allan screw -arrow-.
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Clip wheel speed sensor cable on body and pull through to‐
wards the interior.

– Correctly insert the rubber grommet and plug connection -1-

of the ABS speed sensor.
– Clip in lines for speed sensor with brackets -arrow- to the body.

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Tightening torque:
Screw for wheel speed sensor 8 Nm

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
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 Roomster 2006 ➤
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7.4 Removing and installing the ABS speed

sensor on the rear axle - vehicles as of
11/2012.

Note

The procedure for removal and installation of the speed sensor is

identical for vehicles with drum brakes and for vehicles with disc
brakes.

Removing:
– Raise vehicle.
– Disconnect plug connection -1- for wheel speed sensor cable
from ABS speed sensor.
– Release Allan screw -arrow-.

Note

The wheel speed sensor is shown on the vehicle with disc brakes.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Pull the wheel speed sensor -1- out of thewith
opening in the axle
respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

stud and unclip its cables on the axle.

Installing:
– Insert the wheel speed sensor in the bore of the axle stud and
tighten the Allan screw -arrow-.
– Clip cables for wheel speed sensor on the axle.
– Connect plug connection -1- for wheel speed sensor cable/
ABS speed sensor.

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Tightening torque:
Screw for wheel speed sensor 8 Nm

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

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 Roomster 2006 ➤
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7.5 Repairing rear ABS wheel speed sensor

cables - Vehicles with ABS BOSCH 8.0
Special tools and workshop equipment required
♦ Wiring loom repair kit , e.g. Škoda Car Tool Kit, Order No.: -
S 504 500 V-
♦ Vehicle diagnosis, measurement and information system -
VAS-

Note

The procedure for repairing the ABS speed sensor cables is iden‐
tical for vehicles with drum brakes and for vehicles with disc
brakes.

Removing:
– Disconnect battery ⇒ Electrical System; Rep. gr. 27 .
– Release plug connection on wheel speed sensor and separate
plug connector.
– Unclip wheel speed sensor cable on rear axle and body.
– Removing the seat bench ⇒ Body Work; Rep. gr. 72 .
– Remove trim panel at bottom of pillar C ⇒ Body Work; Rep.
gr. 70 .
– Remove sill panel ⇒ Body Work; Rep. gr. 68 .
– Fold back the floor covering around the seat bench.
– Release the rubber grommet -1- and pull the wheel speed
sensor cable -2- into the vehicle interior.
– Separate the ABS speed sensor cable between crimp con‐
nection -arrow A- and sheathing -arrow B-.
Installing:
– Draw in the new wheel speed sensor cable and attach the
rubber grommet.
– Insulate the two cable extremities with a 6...7 mm wire stripper.
– Twist the two cable extremities.

Note

♦ The insulation of the cable extremities must not be twisted.

♦ Make sure the correct red crimp connector for 0.5 mm 2 is
selected.

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

64
 Roomster 2006 ➤
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– Slide the crimp connector on the cable extremities and crimp

together at both sides with the pliers.

Note

♦ The crimp connector must be heated from the centre towards

the outside until it is fully sealed and the adhesive flows out.
♦ Set the hot-air blower to the relevant temperature according
to the operating instructions.
♦ When heating up the crimp connector, make sure the hot noz‐
zle does not damage any other cables, plastic parts or insu‐
lating materials.

– After pressing on, the crimp connector must be heated with

the hot-air blower.
To do so use the hot-air blower from the wiring loom repair kit.
– If the repair cable was initially insulated, this point must be
rewrapped with yellow insulating tape, or if necessary the ca‐
ble must be attached again with a cable strap.
Further installation occurs in reverse order.
– Install sill panel ⇒ Body Work; Rep. gr. 68 .
– Install trim panel at bottom of pillar C ⇒ Body Work; Rep. gr.
70 .
– Installing the seat bench ⇒ Body Work; Rep. gr. 72 .

Note

Observe the instructions after reattaching the battery ⇒ Electrical

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
System; Rep. gr. 27 .
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Connect battery ⇒ Electrical System; Rep. gr. 27 .

– Perform a vehicle system test using the vehicle diagnosis,
measurement and information system - VAS- ⇒ page 20 .

65
 Roomster 2006 ➤
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8 Removing and installing parts of the

ESP System
⇒ “8.1 Removing and installing sensor unit for ESP G419 ”, page
66
⇒ “8.2 Removing and installing steering angle sender G85 ”, page
69

8.1 Removing and installing sensor unit for

ESP - G419-
Only valid for vehicles with ABS/EDL/TCS/ESP Bosch 8.0

Note

♦ In the sensor unit for ESP - G419- the sender for lateral ac‐
celeration - G200- and the yaw rate sender - G202- are fitted
in one housing.
♦ The sensor unit for ESP - G419- is located below the left front
seat.
♦ The removed unit is sensitive to strong vibrations.
♦ If the unit was exposed to strong vibrations or blows, its proper
operation cannot be guaranteed.

WARNING

Strong vibrations (e.g. fall, knock) can destroy the sensor unit
for ESP - G419- The sensor unit for ESP - G419- must no lon‐
ger be used.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Special tools and workshop equipment required
♦ Vehicle diagnosis, measurement and information system -
VAS-
Removing:

WARNING

♦ Disconnect earth strap from the battery with the ignition

off before commencing work on the electrical system.

– Disconnect battery ⇒ Electrical System; Rep. gr. 27

– Remove left front seat ⇒ Body Work; Rep. gr. 72
– Remove trim panel at bottom of pillar B ⇒ Body Work; Rep.
gr. 70
– Partially remove trim panel at bottom of pillar A ⇒ Body Work;
Rep. gr. 70

Note

♦ The unit is located under the floor covering of the left front seat
before the cross member.
♦ -Arrow- in Fig. S45-0113 points in the travel direction.

66
 Roomster 2006 ➤
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– Unplug plug -1- from the unit -3-.

– Unscrew nuts -2- and remove unit -3-.
Installing:
Installation is performed in the reverse order, pay attention to the
following points:

Note

Observe the instructions after reattaching the battery ⇒ Electrical

System; Rep. gr. 27

– Connect battery ⇒ Electrical System; Rep. gr. 27

– Perform a vehicle system test using the vehicle diagnosis,
measurement and information system - VAS- ⇒ page 20

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

8. Removing and installing parts of the ESP System 67

 Roomster 2006 ➤
Brake systems - Edition 02.2014

Tightening torques:
Sensor unit for ESP - G419- to body 6 Nm

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

68
 Roomster 2006 ➤
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8.2 Removing and installing steering angle

sender - G85-

Note

The steering angle sender -G85- is integrated together with the

coil spring into a housing.

A description of the structure and function of the steering angle

sender -G85- can be found in self-study programme no. 42.
The steering angle sender is attached at the steering column
switch.
Removing and installing:
⇒ Electrical system; Rep. gr. 94 (Chapter: Removing and instal‐
ling restoring ring with slip ring from steering column switch
– Then the basic setting of the steering angle sender - G85- must
be performed ⇒ Vehicle diagnostic tester

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

69
 Roomster 2006 ➤
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9 ABS BOSCH 8.2

⇒ “9.1 Summary of Components of Hydraulic Control Unit, Brake
Servo Unit/Master Brake Cylinder ABS BOSCH 8.2 - left-hand
drive”, page 70
⇒ “9.2 Connection of the brake lines from the master brake cyl‐
inder to the hydraulic unit ABS BOSCH 8.2 - left-hand drive”, page
72
⇒ “9.3 Removing and installing control unit and hydraulic unit ABS
BOSCH 8.2 - left-hand drive”, page 72
⇒ “9.4 Summary of Components of Hydraulic Control Unit, Brake
Servo Unit/Master Brake Cylinder ABS BOSCH 8.2 - right-hand
drive”, page 74
⇒ “9.5 Connection of the brake lines from the master brake cyl‐
inder to the hydraulic unit ABS BOSCH 8.2 - right-hand drive”,
page 76
⇒ “9.6 Removing and installing control unit and hydraulic unit ABS
BOSCH 8.2 - right-hand drive”, page 76

9.1 Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Mas‐

ter Brake Cylinder ABS BOSCH 8.2 - left-hand drive

1 - ABS control unit - J104-

❑ Remove and install ABS
hydraulic unit - N55-
with ABS control unit -
J104- ⇒ page 72
2 - ABS hydraulic unit - N55-
❑ The ABS return flow
pump - V39- and the
valve block must not be
separated from each
other
❑ when replacing the hy‐
draulic unit, it is abso‐
lutely necessary to seal
off the old part with a
screw plug from the re‐
pair kit -1H0 698 311 A-
❑ Remove and install ABS
hydraulic unit - N55-
with ABS control unit -
J104- ⇒ page 72
3 - Connection of brake line
❑ from the hydraulic unit to
the front right brake cal‐
iper
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ Marking on the hydraul‐ unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
ic unit -FR- with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

4 - Connection of brake line

❑ to brake caliper/rear left
wheel cylinder
❑ Marking on the hydraul‐
ic unit -RL-
5 - Connection of brake line
❑ to brake caliper/rear
right wheel cylinder

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 Roomster 2006 ➤
Brake systems - Edition 02.2014
❑ Marking on the hydraulic unit -RR-
6 - Connection of brake line
❑ from hydraulic unit to front left brake caliper
❑ Marking on the hydraulic unit -FL-
7 - Connection of brake line
❑ from master brake cylinder (push rod piston circuit) to hydraulic unit
❑ Marking on the hydraulic unit -HZ1-
8 - Connection of brake line
❑ from master brake cylinder (floating piston circuit) to hydraulic unit
❑ Marking on the hydraulic unit -HZ2-
9 - Gasket
❑ for brake servo unit
10 - Brake servo unit
❑ removing and installing ⇒ page 189
11 - Nut, 25 Nm
12 - Compression ring
❑ replace
13 - Nut, 25 Nm
14 - Master brake cylinder
❑ No provision is made for repair; a defective cylinder must be completely replaced
❑ removing and installing ⇒ page 181
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
15 - Retaining pin for brake
unless fluidbyreservoir
authorised ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ fit through the master brake cylinder
16 - Plugs
❑ moisten with brake fluid, insert in the master brake cylinder and press in the brake fluid reservoir
17 - Plugs
❑ Outlet for vacuum line
18 - Brake fluid reservoir
19 - Cap
20 - Nut, 20 Nm
21 - Support
22 - Bolt, 8 Nm

9. ABS BOSCH 8.2 71

 Roomster 2006 ➤
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9.2 Connection of the brake lines from the

master brake cylinder to the hydraulic
unit ABS BOSCH 8.2 - left-hand drive
On master brake cylinder:
A - from master brake cylinder (push rod piston circuit) to hy‐
draulic unit
B - from master brake cylinder (floating piston circuit) to hydraulic
unit
2 - from hydraulic unit to brake caliper/rear left wheel cylinder
3 - from hydraulic unit to brake caliper/rear right wheel cylinder
4 - from hydraulic unit to front left brake caliper

On the hydraulic unit

A - from hydraulic unit to master brake cylinder (push rod piston
circuit)
- Marking on the hydraulic unit -HZ1-
B - from hydraulic unit to master brake cylinder (floating piston
circuit)
- Marking on the hydraulic unit -HZ2-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
1 - from the hydraulic
unless authorised byunit
ŠKODAto the
AUTOfront right AUTO
A. S. ŠKODA brake caliper
A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
- Marking on the hydraulic unit -FR-
2 - from hydraulic unit to brake caliper/rear left wheel cylinder
- Marking on the hydraulic unit -RL-
3 - from hydraulic unit to brake caliper/rear right wheel cylinder
- Marking on the hydraulic unit -RR-
4 - from hydraulic unit to front left brake caliper
- Marking on the hydraulic unit -FL-

9.3 Removing and installing control unit and

hydraulic unit ABS BOSCH 8.2 - left-
hand drive
Removing
Special tools and workshop equipment required
♦ Brake pedal load , e.g. -V.A.G 1869/2-
♦ Repair kit for plugs -1H0 698 311 A-
Fitting position:
The control unit is bolted to the hydraulic unit and is located on
the right of the engine compartment.

Caution

The brake lines around the hydraulic unit must not be bent!

– Disconnect battery ⇒ Electrical System; Rep. gr. 27 .

72
 Roomster 2006 ➤
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– Remove engine cover ⇒ engine; Rep. gr. 10 .

For vehicles with 1.4 ltr. engine:
– Detach the hose between the non-return valve and the cam‐
shaft housing.
Vehicles with engines TDI CR DPF (diesel particle filter)
– Remove engine cover.
– Remove the cooling water tank cover ⇒ Body Work; Rep. gr.
66 .
– Disconnect plug -1...4- for diesel particle filter and lambda
probe.
– Remove the holder with the plug from the bulkhead plenum
chamber and lay to the side.
– Pull the engine control unit out of the bracket and lay to the
side.
– Remove engine control unit bracket.
– Remove the insulation from the bulkhead plenum chamber.
– Remove bulkhead ⇒ Body work; Rep. gr. 66 .
Continued for all vehicles

– Press down the red fuse -arrow-.

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

– Unlock the plug connection of the control unit -arrow- and pull
out towards the front.
– Insert brake pedal load , e.g. -V.A.G 1869/2-
– Press brake pedal and lock in place with brake pedal load ,
e.g. -V.A.G 1869/2- , at least 60 mm.
– Attach the bleeder hose of the bleeding bottle onto the vent
valve of the front left brake caliper and open bleeder valve.
– Shut the vent valve once the brake fluid flowed out.
– Disconnect the bleeder hose from the vent valve.
– Place sufficient non-fluffing cloths under the control unit and
the hydraulic unit.
Make sure that no brake fluid gets onto the contacts of the plug
connections.
– Mark the brake lines of the hydraulic unit -A and B- to the
master brake cylinder.

9. ABS BOSCH 8.2 73

 Roomster 2006 ➤
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– Unscrew the brake lines of the hydraulic unit and of the master
brake cylinder, unclip from the bracket and lay to the side.
– Close the brake lines and threaded holes immediately with
plugs from the repair kit -1H0 698 311 A- .
– Mark the remaining brake lines (to brake calipers) -1…4-, un‐
screw from the hydraulic unit and seal off.

– Pull hydraulic unit with control unit upwards and out of the
bracket.
– Slacken nuts -1- and remove bracket (if it is necessary to re‐
move the bracket).
Install

Note

♦ New hydraulic control units are filled with brake fluid and pre-
bled.
♦ Only then remove plugs from the new hydraulic unit when the
relevant brake line is installed.
♦ If the sealing plugs were already removed from the hydraulic
unit, then brake fluid may escape and adequate filling and
bleeding can no longer be guaranteed.
♦ When installing, pay attention that the rubber bearings are not
pressed out of the bracket.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Further installation occurs
unless authorised by ŠKODA in AUTO
reverse order.AUTO A. S. does not guarantee or accept any liability
A. S. ŠKODA
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Make sure that the multi-pin plug connection latches correctly
with the ABS control unit - J104- .
– Remove brake pedal load , e.g. -V.A.G 1869/2- , -V.A.G
1869/2- .
– Bleed brake system ⇒ page 198 .
– Code new ABS control unit - J104- ⇒ Vehicle diagnostic tester
and adapt.
– Connect the battery and carry out any additional measures
after reconnecting the battery ⇒ Electrical System; Rep. gr.
27 .
Tightening torques:
Bolt to hydraulic unit 8 Nm
Nuts to body 20 Nm
Brake lines to ABS unit:
Thread M 10 × 1 14 Nm
Thread M 12 × 1 14 Nm

9.4 Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Mas‐

ter Brake Cylinder ABS BOSCH 8.2 - right-hand drive

74
 Roomster 2006 ➤
Brake systems - Edition 02.2014

1 - Brake servo unit

❑ removing and installing
⇒ page 191
2 - Connection of brake line
❑ to brake caliper/rear
right wheel cylinder
❑ Marking on the hydraul‐
ic unit -RR-
3 - Connection of brake line
❑ to brake caliper/rear left
wheel cylinder
❑ Marking on the hydraul‐
ic unit -RL-
4 - Connection of brake line
❑ from the hydraulic unit to
the front right brake cal‐
iper
❑ Marking on the hydraul‐
ic unit -FR-
5 - ABS control unit - J104-
❑ Remove and install ABS
hydraulic unit - N55-
with ABS control unit -
J104- ⇒ page 76
6 - ABS hydraulic unit - N55-
❑ The ABS return flow
pump - V39- and the
valve block must not be
separated from each
other
❑ when replacing the hy‐
draulic unit, it is abso‐
lutely necessary to seal
off the old part with a
screw plug from the repair kit -1H0 698 311 A-
❑ Remove and install ABS hydraulic unit - N55- with ABS control unit - J104- ⇒ page 76
7 - Connection of brake line
❑ from hydraulic unit to front left brake caliper
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ Marking on the hydraulic unit -FL-with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

8 - Connection of brake line

❑ from master brake cylinder (floating piston circuit) to hydraulic unit
❑ Marking on the hydraulic unit -HZ2-
9 - Connection of brake line
❑ from master brake cylinder (push rod piston circuit) to hydraulic unit
❑ Marking on the hydraulic unit -HZ1-
10 - Rubber shock absorber bushing
11 - Support
12 - 20 Nm
❑ replace after each removal
13 - Bolt, 8 Nm

9. ABS BOSCH 8.2 75

 Roomster 2006 ➤
Brake systems - Edition 02.2014

9.5 Connection of the brake lines from the

master brake cylinder to the hydraulic
unit ABS BOSCH 8.2 - right-hand drive
On master brake cylinder:
A - from master brake cylinder (push rod piston circuit) to hy‐
draulic unit
B - from master brake cylinder (floating piston circuit) to hydraulic
unit
4 - from the hydraulic unit to the front right brake caliper

On the hydraulic unit:

A - from hydraulic unit to master brake cylinder (push rod piston
circuit)
- Marking on the hydraulic unit -HZ1-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
B - from hydraulic unit to master brake cylinder (floating pistonby ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
unless authorised
circuit) with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

- Marking on the hydraulic unit -HZ2-

1 - from hydraulic unit to rear left brake caliper/wheel-brake cyl‐
inder
- Marking on the hydraulic unit -RL-
2 - from hydraulic unit to rear right brake caliper/wheel-brake cyl‐
inder
- Marking on the hydraulic unit -RR-
3 - from hydraulic unit to front left brake caliper
- Marking on the hydraulic unit -FL-
4 - from the hydraulic unit to the front right brake caliper
- Marking on the hydraulic unit -FR-

9.6 Removing and installing control unit and

hydraulic unit ABS BOSCH 8.2 - right-
hand drive
Special tools and workshop equipment required
♦ Brake pedal load , e.g. -V.A.G 1869/2-
♦ Repair kit for plugs -1H0 698 311 A-

76
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Removing
Fitting position:
The control unit is bolted to the hydraulic unit and is located on
the left in the engine compartment -2-.

Caution

The brake lines around the hydraulic unit must not be bent!

– Disconnect battery ⇒ Electrical System; Rep. gr. 27 .

– Remove engine cover ⇒ engine; Rep. gr. 10 .
– Remove air filter ⇒ Engine; Rep. gr. 24 (fuel engines) or ⇒
Engine; Rep. gr. 23 (diesel engines).
– Remove battery and battery tray ⇒ Electrical System; Rep.
gr. 27 .

– Press fuse -2- in -direction of arrow-.

– Unlock fuse -1- for plug -3-.
– Unplug connector -3-.

– Press brake pedal and lock in place with brake pedal load, e.g.
-V.A.G 1869/2- , at least 60 mm.
– Fit the bleeder hose of the bleeding bottle onto the vent valve
of the front left brake calliper.
– Fit the bleeder hose of the bleeding bottle onto the vent valve
of the rear left brake calliper (wheel-brake cylinder).
– Open vent valves.
– Shut the vent valves once the brake fluid has flown out.
– Disconnect the bleeder hose from the vent valve.
– Place sufficient non-fluffing cloths under the control unit and
the hydraulic unit.

Caution

Make sure that no brake fluid gets onto the contacts of the plug
connections.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

9. ABS BOSCH 8.2 77

 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Mark the brake lines from the master brake cylinder to the hy‐
draulic unit -A and B- and unscrew from the hydraulic unit.
– Close the brake lines and threaded holes immediately with
plugs from the repair kit -1H0 698 311 A- .
– Mark the remaining brake lines -1...4- and unscrew from the
hydraulic unit.
– Close the brake lines and threaded holes immediately with
plugs from the repair kit -1H0 698 311 A- .

– Pull hydraulic unit with control unit upwards and out of the
bracket.
– Slacken nuts and remove bracket (if it is necessary to remove
the bracket).
Installing:

Note

♦ New control units are filled with brake fluid and are pre-bled.
♦ Only then remove plugs from the new hydraulic unit when the
relevant brake line is installed.
♦ If the plugs were already removed from the unit, then brake
fluid may escape and adequate filling and bleeding can no
longer be guaranteed.
♦ When installing, pay attention that the rubber bearing is cor‐
rectly fitted in the bracket.

Further installation occurs in reverse order.

– Make sure that the multi-pin plug connection latches correctly
with the ABS control unit - J104- .
– Remove the brake pedal load , e.g. -V.A.G 1869/2- .
– Bleeding Brake System ⇒ page 198
– Code ABS control unit
Protected - J104-Copying
by copyright. ⇒ Vehicle diagnostic
for private or commercial tester.
purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Connect the battery andtocarry
with respect out any
the correctness additional
of information in thismeasures
document. Copyright by ŠKODA AUTO A. S.�
after reconnecting the battery ⇒ Electrical System; Rep. gr.
27 .

78
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Tightening torques:
Bolt to hydraulic unit 8 Nm
Nuts to body 20 Nm
♦ Use new nut!

Brake lines to ABS unit:

Thread M 10 x 1 14 Nm
Thread M 12 x 1 14 Nm

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

79
 Roomster 2006 ➤
Brake systems - Edition 02.2014

10 ABS/EDL/TCS/ESP BOSCH 8.2i

⇒ “10.1 Summary of Components of Hydraulic Control Unit, Brake
Servo Unit/Master Brake Cylinder ABS/EDL/TCS/ESP BOSCH
8.2i - left-hand drive”, page 80
⇒ “10.2 Connection of the brake lines from the master brake cyl‐
inder to the hydraulic unit ABS/EDL/TCS/ESP BOSCH 8.2i - left-
hand drive”, page 82
⇒ “10.3 Remove and install control unit and hydraulic unit ABS/
EDL/TCS/ESP BOSCH 8.2i - left-hand drive”, page 82
⇒ “10.4 Summary of Components of Hydraulic Control Unit, Brake
Servo Unit/Master Brake Cylinder ABS/EDL/TCS/ESP BOSCH
8.2i - right-hand drive”, page 85
⇒ “10.5 Connection of the brake lines from the master brake cyl‐
inder to the hydraulic unit ABS/EDL/TCS/ESP BOSCH 8.2i - right-
hand drive”, page 87
⇒ “10.6 Remove and install control unit and hydraulic unit ABS/
EDL/TCS/ESP BOSCH 8.2i - right-hand drive”, page 88

10.1 Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Mas‐

ter Brake Cylinder ABS/EDL/TCS/ESP BOSCH 8.2i - left-hand drive

1 - ABS control unit - J104-

❑ Remove and install ABS
hydraulic unit - N55-
with ABS control unit -
J104- ⇒ page 82
❑ with integrated sensor
unit for ESP -G419-
2 - ABS hydraulic unit - N55-
❑ The ABS return flow
pump - V39- and the
valve block must not be
separated from each
other
❑ when replacing the hy‐
draulic unit, it is abso‐
lutely necessary to seal
off the old part with a
screw plug from the re‐
pair kit -1H0 698 311 A- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ Remove and install ABS with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
hydraulic unit - N55-
with ABS control unit -
J104- ⇒ page 82
3 - Connection of brake line
❑ from the hydraulic unit to
the front right brake cal‐
iper
❑ Marking on the hydraul‐
ic unit -FR-
❑ with thread M 10 x 1
4 - Connection of brake line
❑ to brake caliper/rear
right wheel cylinder
❑ Marking on the hydraul‐
ic unit -RR-

80
 Roomster 2006 ➤
Brake systems - Edition 02.2014
❑ with thread M 10 x 1
5 - Connection of brake line
❑ from hydraulic unit to front left brake caliper
❑ Marking on the hydraulic unit -FL-
❑ with thread M 12 x 1
6 - Connection of brake line
❑ to brake caliper/rear left wheel cylinder
❑ Marking on the hydraulic unit -RL-
❑ with thread M 12 x 1
7 - Connection of brake line
❑ from master brake cylinder (push rod piston circuit) to hydraulic unit
❑ Marking on the hydraulic unit -HZ1-
❑ with thread M 12 x 1
8 - Connection of brake line
❑ from master brake cylinder (floating piston circuit) to hydraulic unit
❑ Marking on the hydraulic unit -HZ2-
❑ with thread M 12 x 1
9 - Nut, 8 Nm
❑ 3 x on rubber bearing
❑ at the top on the side 1 × nut, which must be unscrewed, otherwise no removal or installation is possible
❑ at the bottom 2 × nut with washer, which must be unscrewed until the rubber bearing can be turned
10 - Gasket
❑ for brake servo unit
11 - Brake servo unit
❑ removing and installing ⇒ page 189
12 - Self-locking nut, 25 Nm
13 - Compression ring
❑ replace
14 - Self-locking nut, 25 Nm
15 - Master brake cylinder
❑ No provision is made for repair; a defective cylinder must be completely replaced
❑ removing and installing ⇒ page 181
16 - Retaining pin for brake fluid reservoir
❑ fit through the master brake cylinder
17 - Plugs
❑ moisten with brake fluid, insert in the master brake cylinder and press in the brake fluid reservoir
18 - Plugs
❑ Connection for vacuum hose
19 - Brake fluid reservoir
20 - Cap
21 - Self-locking nut, 20Copying
Protected by copyright. Nm for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
22 - Threaded bores
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

❑ Threaded bore is welded to the body

23 - Self-locking nut, 20 Nm
24 - Threaded bores
❑ Threaded bore is welded to the body

10. ABS/EDL/TCS/ESP BOSCH 8.2i 81

 Roomster 2006 ➤
Brake systems - Edition 02.2014

25 - Support

10.2 Connection of the brake lines from the

master brake cylinder to the hydraulic
unit ABS/EDL/TCS/ESP BOSCH 8.2i -
left-hand drive
On master brake cylinder:
A - from master brake cylinder (push rod piston circuit) to hy‐
draulic unit
B - from master brake cylinder (floating piston circuit) to hydraulic
unit
2 - from hydraulic unit to brake caliper/rear left wheel cylinder
3 - from hydraulic unit to brake caliper/rear right wheel cylinder
4 - from hydraulic unit to front left brake caliper

On the hydraulic unit

A - from hydraulic unit to master brake cylinder (push rod piston
circuit)
- Marking on the hydraulic unit -HZ1-
B - from hydraulic unit to master brake cylinder (floating piston
circuit)
- Marking on the hydraulic unit -HZ2-
1 - from the hydraulic unit to the front right brake caliper
- Marking on the hydraulic unit -FR-
2 - from hydraulic unit to brake caliper/rear left wheel cylinder
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
- Marking on the
unless authorised hydraulic
by ŠKODA AUTO A.unit -RL-AUTO A. S. does not guarantee or accept any liability
S. ŠKODA
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
3 - from hydraulic unit to brake caliper/rear right wheel cylinder
- Marking on the hydraulic unit -RR-
4 - from hydraulic unit to front left brake caliper
- Marking on the hydraulic unit -FL-

10.3 Remove and install control unit and hy‐

draulic unit ABS/EDL/TCS/ESP BOSCH
8.2i - left-hand drive
Special tools and workshop equipment required
♦ Brake pedal load , e.g. -V.A.G 1869/2-
♦ Repair kit for plugs -1H0 698 311 A-
Removing
Fitting position:
The control unit is bolted to the hydraulic unit and is located on
the right of the engine compartment.

82
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Caution

The brake lines around the hydraulic unit must not be bent!

Removing
– Disconnect battery ⇒ Electrical System; Rep. gr. 27 .
– Remove engine cover ⇒ engine; Rep. gr. 10 .
For vehicles with 1.4 ltr. engine:
– Detach the hose between the non-return valve and the cam‐
shaft housing.
Vehicles with engines TDI CR DPF (diesel particle filter)
– Remove engine cover.
– Remove the cooling water tank cover ⇒ Body Work; Rep. gr.
66 .
– Disconnect plug -1...4- for diesel particle filter and lambda
probe.
– Remove the holder with the plug from the bulkhead plenum
chamber
Protectedand lay toCopying
by copyright. the side.
for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Remove intake
with respect hose
to the and ofairinformation
correctness filter housing.
in this document. Copyright by ŠKODA AUTO A. S.�

– Pull the engine control unit out of the bracket and lay to the
side.
– Remove engine control unit bracket.
– Remove the insulation from the bulkhead plenum chamber.
– Remove bulkhead ⇒ Body work; Rep. gr. 66 .
Continued for all vehicles

– Press down the red fuse -arrow-.

10. ABS/EDL/TCS/ESP BOSCH 8.2i 83

 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Unlock the plug connection of the control unit -arrow- and pull
out towards the front.
– Insert brake pedal load , e.g. -V.A.G 1869/2-
– Press brake pedal and lock in place with brake pedal load ,
e.g. -V.A.G 1869/2- , at least 60 mm.
– Attach the bleeder hose of the bleeding bottle onto the vent
valve of the front left brake caliper and open bleeder valve.
– Shut the vent valve once the brake fluid flowed out.
– Place sufficient non-fluffing cloths under the control unit and
the hydraulic unit.
Make sure that no brake fluid gets onto the contacts of the plug
connections.
– Mark the brake lines of the hydraulic unit -A and B- to the
master brake cylinder.

– Unscrew the brake lines of the hydraulic unit and of the master
brake cylinder, unclip from the bracket and lay to the side.
– Close the brake lines and threaded holes immediately with
plugs from the repair kit -1H0 698 311 A- .
– Mark the remaining brake lines (to brake calipers) -1…4-, un‐
screw from the hydraulic unit and seal off.

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

84
 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Slacken 3 nuts -1- of the rubber bearing.

– Release nut (top side), otherwise the removal is not possible.
– Pull hydraulic unit with control unit upwards and out of the
bracket.
– Slacken nuts and remove bracket (if it is necessary to remove
the bracket).
Install

Note

♦ Only then remove plugs from the new hydraulic unit when the
relevant brake line is installed.
♦ If the sealing plugs were already removed from the hydraulic
unit, then brake fluid may escape and adequate filling and
bleeding can no longer be guaranteed.
♦ When installing, pay attention that the rubber bearing is cor‐
rectly fitted in the bracket.

– Further installation occurs in reverse order.

– Make sure that the multi-pin plug connection latches correctly
with the ABS control unit - J104- .
Remove brake pedal load , e.g. -V.A.G 1869/2- , -V.A.G 1869/2- .
– Bleed brake system ⇒ page 198 .
– Code the control unit - J104- ⇒ Vehicle diagnostic tester.
While doing so, a basic setting of the steering angle sender -
G85- , the lateral acceleration sender - G200- , the brake pressure
sender 1 - G201- and the longitudinal acceleration sender - G251-
must be performed ⇒ Vehicle diagnostic tester.
– Connect the battery and carry out any additional measures
after reconnecting the battery ⇒ Electrical System; Rep. gr.
27 .
Tightening torques:
Nut for rubber bearing 8 Nm
Nuts to body 20 Nm
Brake lines to ABS unit:
Thread M 10 x 1 14 Nm
Thread M 12 x 1 14 Nm

10.4 Summary of Components of Hydraulic Control Unit, Brake Servo Unit/Mas‐

ter Brake Cylinder ABS/EDL/TCS/ESP BOSCH 8.2i - right-hand drive

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

10. ABS/EDL/TCS/ESP BOSCH 8.2i 85

 Roomster 2006 ➤
Brake systems - Edition 02.2014

1 - Connection of brake line

❑ from the hydraulic unit to
the front right brake cal‐
iper
❑ Marking on the hydraul‐
ic unit -FR-
❑ with thread M 10 × 1
2 - Connection of brake line
❑ to brake caliper/rear left
wheel cylinder
❑ Marking on the hydraul‐
ic unit -RL-
❑ with thread M 12 × 1
3 - Connection of brake line
❑ to brake caliper/rear
right wheel cylinder
❑ Marking on the hydraul‐
ic unit -RR-
❑ with thread M 10 × 1
4 - Connection of brake line
❑ from hydraulic unit to
front left brake caliper
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ Marking on the hydraul‐ unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
ic unit -FL- with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

❑ with thread M 12 × 1
5 - ABS control unit - J104-
❑ Remove and install ABS
hydraulic unit - N55-
with ABS control unit -
J104- ⇒ page 88
❑ with integrated sensor
unit for ESP -G419-
6 - Nuts, 8 Nm
❑ 3 × on rubber bearing
❑ at the top on the side 1 × nut, which must be unscrewed, otherwise no removal or installation is possible
❑ at the bottom 2 × nut with washer, which must be unscrewed until the rubber bearing can be turned
7 - ABS hydraulic unit - N55-
❑ The ABS return flow pump - V39- and the valve block must not be separated from each other
❑ when replacing the hydraulic unit, it is absolutely necessary to seal off the old part with a screw plug from
the repair kit -1H0 698 311 A-
❑ Remove and install ABS hydraulic unit - N55- with ABS control unit - J104- ⇒ page 88
8 - Self-locking nuts, 20 Nm
9 - Support
10 - Brake servo unit
❑ removing and installing ⇒ page 191
11 - Connection of brake line
❑ from hydraulic unit (push rod piston circuit) to main braking cylinder
❑ Marking on the hydraulic unit -HZ1-
❑ with thread M 12 × 1
12 - Connection of brake line
❑ from hydraulic unit (floating piston circuit) to main braking cylinder

86
 Roomster 2006 ➤
Brake systems - Edition 02.2014
❑ Marking on the hydraulic unit -HZ2-
❑ with thread M 12 × 1
13 - Connection of brake line
❑ from master brake cylinder (push rod piston circuit) to hydraulic unit
❑ Marking on the hydraulic unit -HZ1-
❑ with thread M 12 × 1
14 - Connection of brake line
❑ from master brake cylinder (floating piston circuit) to hydraulic unit
❑ Marking on the hydraulic unit -HZ2-
❑ with thread M 12 × 1

10.5 Connection of the brake lines from the

master brake cylinder to the hydraulic
unit ABS/EDL/TCS/ESP BOSCH 8.2i -
right-hand drive
On master brake cylinder:
A - from master brake cylinder (push rod piston circuit) to hy‐
draulic unit
B - from master brake cylinder (floating piston circuit) to hydraulic
unit
4 - from the hydraulic unit to the front right brake caliper

On the hydraulic unit:

A - from hydraulic unit to master brake cylinder (push rod piston
circuit)
- Marking on the hydraulic unit -HZ1-
B - from hydraulic unit to master brake cylinder (floating piston
circuit)
- Marking on the hydraulic unit -HZ2-
1 - from hydraulic unit to rear left brake caliper/wheel-brake cyl‐
inder
- Marking on the hydraulic unit -RL-
2 - from hydraulic unit to rear right brake caliper/wheel-brake cyl‐
inder
- Marking on the hydraulic unit -RR-
3 - from
Protected hydraulic
by copyright. Copyingunit to front
for private left brake
or commercial caliper
purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
- Marking
with oncorrectness
respect to the the hydraulic unit
of information -FL-
in this document. Copyright by ŠKODA AUTO A. S.�

4 - from the hydraulic unit to the front right brake caliper

- Marking on the hydraulic unit -FR-

10. ABS/EDL/TCS/ESP BOSCH 8.2i 87

 Roomster 2006 ➤
Brake systems - Edition 02.2014

10.6 Remove and install control unit and hy‐

draulic unit ABS/EDL/TCS/ESP BOSCH
8.2i - right-hand drive
Special tools and workshop equipment required
♦ Brake pedal load , e.g. -V.A.G 1869/2-
♦ Repair kit for plugs -1H0 698 311 A-
Removing
Fitting position:
The control unit is bolted to the hydraulic unit and is located on
the left in the engine compartment -2-.

Caution

The brake lines around the hydraulic unit must not be bent!

– Disconnect battery ⇒ Electrical System; Rep. gr. 27 .

– Remove engine cover ⇒ engine; Rep. gr. 10 .
– Remove air filter ⇒ Engine; Rep. gr. 24 (fuel engines) or ⇒
Engine; Rep. gr. 23 (diesel engines).
– Remove battery and battery tray ⇒ Electrical System; Rep.
gr. 27 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Press fuse -2- in -direction of arrow-.
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Unlock fuse -1- for plug -3-.

– Unplug connector -3-.

88
 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Press brake pedal and lock in place with brake pedal load, e.g.
-V.A.G 1869/2- , at least 60 mm.
– Fit the bleeder hose of the bleeding bottle onto the vent valve
of the front left brake calliper.
– Fit the bleeder hose of the bleeding bottle onto the vent valve
of the rear left brake calliper (wheel-brake cylinder).
– Open vent valves.
– Shut the vent valves once the brake fluid has flown out.
– Disconnect the bleeder hose from the vent valve.
– Place sufficient non-fluffing cloths under the control unit and
the hydraulic unit.

Caution

Make sure that no brake fluid gets onto the contacts of the plug
connections.

– Mark the brake lines from the master brake cylinder to the hy‐
draulic unit -A and B- and unscrew from the hydraulic unit.
– Close the brake lines and threaded holes immediately with
plugs from the repair kit -1H0 698 311 A- .
– Mark the remaining brake lines -1...4- and unscrew from the
hydraulic unit.
– Close the brake lines and threaded holes immediately with
plugs from the repair kit -1H0 698 311 A- .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

10. ABS/EDL/TCS/ESP BOSCH 8.2i 89

 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Slacken 3 nuts -arrows- of the rubber bearing.

It must be possible to turn the rubber bearing.
– Pull hydraulic unit with control unit upwards and out of the
bracket.
– Slacken nuts and remove bracket (if it is necessary to remove
the bracket).
Installing:

Note

♦ New control units are filled with brake fluid and are pre-bled.
♦ Only then remove plugs from the new hydraulic unit when the
relevant brake line is installed.
♦ If the plugs were already removed from the unit, then brake
fluid may escape and adequate filling and bleeding can no
longer be guaranteed.
♦ When installing, pay attention that the rubber bearing is cor‐
rectly fitted in the bracket.

Further installation occurs in reverse order.

– Make sure that the multi-pin plug connection latches correctly
with the ABS control unit - J104- .
– Remove the brake pedal load , e.g. -V.A.G 1869/2- .
– Bleeding Brake System
AUTO⇒A.page 198
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Code ABS control unit - J104- ⇒ Vehicle diagnostic tester.
While doing so, a basic setting of the steering angle sender -
G85- , the lateral acceleration sender - G200- , the brake pressure
sender 1 - G201- and the longitudinal acceleration sender - G251-
must be performed ⇒ Vehicle diagnostic tester.
– Connect the battery and carry out any additional measures
after reconnecting the battery ⇒ Electrical System; Rep. gr.
27 .

90
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Tightening torques:
Nut for rubber bearing 8 Nm
Nuts to body 20 Nm
♦ Use new nut!

Brake lines to ABS unit:

Thread M 10 x 1 14 Nm
Thread M 12 x 1 14 Nm

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

91
 Roomster 2006 ➤
Brake systems - Edition 02.2014

46 – Brakes - mechanism
1 Repairing front wheel brake
⇒ “1.1 Changing the brake pads of the front brake - Mounting
instructions”, page 92
⇒ “1.2 Repairing front wheel brake - Floating caliper disc brake
FS-IIl”, page 92
⇒ “1.3 Removing and installing brake pads and floating caliper
disc brake FS-III”, page 94
⇒ “1.4 Repairing front wheel brake - Floating caliper disc brake
C54”, page 99
⇒ “1.5 Removing and installing brake pads and floating caliper
disc brake C54”, page 102
⇒ “1.6 Repairing front wheel brake, brake caliper FN3”,
page 105
⇒ “1.7 Removing and installing brake pads for brake caliper FN3”,
page 106
⇒ “1.8 Removing and installing brake caliper FN3”, page 109

1.1 Changing the brake pads of the front

brake - Mounting instructions
When changing the pad, observe the following:
– Check protective collar of brake caliper piston.
Replace the protective collar if damaged.
When replacing the collar:
– Check the contact surfaces of the brake piston and the brake
caliper for any dirt (oxydation).
Carefully clean the piston as well as the brake caliper if dirty and
replace the sealing sleeve.
– Check the brake piston and the brake caliper (corrosion,
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
grooves on the outside of theunless
cylinder surface),
authorised replace
by ŠKODA AUTO A. S. the
ŠKODA AUTO A. S. does not guarantee or accept any liability
brake caliper completely if damaged.
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

For brake caliper piston, press into the initial position:

– Check if the piston can be slightly pressed into the brake cal‐
iper.
If the piston cannot be slightly pressed into the brake caliper:
– Check and clean the brake piston as well as the brake caliper,
replace sealing sleeve and protective collar.
Replace the brake caliper completely if damaged.

1.2 Repairing front wheel brake - Floating

caliper disc brake FS-IIl
Special tools and workshop equipment required
♦ Piston jig - MP9-403-
♦ Brake pedal load , e.g. -V.A.G 1869/2-
♦ Brake filling and bleeding device , e. g. -VAS 5234-
♦ Bleeding bottle (commercially available)

92 Rep. gr.46 - Brakes - mechanism

 Roomster 2006 ➤
Brake systems - Edition 02.2014

♦ Brake fluid ⇒ page 13

Note

♦ Observe the instructions for changing the pad ⇒ page 92

♦ After replacing the brake pads, depress brake pedal firmly
several times when the vehicle is stationary to ensure the
brake pads are properly seated in their normal operating po‐
sition.
♦ Use the brake pedal load , e.g. -V.A.G 1869/2- before remov‐
ing a brake caliper or separating a brake hose from the brake
caliper. -V.A.G 1869/2- .
♦ Use a bleeding bottle, that only comes into contact with the
brake fluid, to drain brake fluid from the brake fluid reservoir.
Brake fluid is toxic and must never be sucked up by mouth!
♦ Already used brake fluid must never be used again.
♦ Tightening torque of the wheel screws 120 Nm.

Summary of components of front brake FS-III

1 - Brake disc
❑ Assignment, dimen‐
sions and wear limit
⇒ page 1
❑ always replace axle-
wise
❑ unscrew the brake cali‐
per before removing
❑ Do not use force to sep‐
arate the brake discs
from the wheel hub, if
necessary use rust sol‐
vent;Protected
as youbycould oth‐
copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
erwise damage
unless authorisedthe
by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
brake discs
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

2 - Screw, 4 Nm
3 - Brake pads
❑ with wear indicator (de‐
pending on the vehicle
equipment, only up to
MY 2010)
– with a corresponding
wear (limit: 2 to 3mm) a
warning light in the dash
panel insert lights up
(depending on the vehi‐
cle equipment, only up
to MY 2010)
❑ with retaining spring
❑ Insert the inner brake
pad (with the large 3-fin‐
ger clip with metallic
gloss and with the mark‐
ing “piston side” on the
steel supporting plate)
on the piston side.
❑ Thickness, wear limit ⇒ page 1

1. Repairing front wheel brake 93

 Roomster 2006 ➤
Brake systems - Edition 02.2014
❑ Inspect thickness ⇒ Maintenance ; Booklet Roomster
❑ always replace axle-wise
❑ to not unscrew the brake hose when replacing the brake pad
❑ removing and installing ⇒ page 94
❑ Do not exchange the inner brake pad (with the large 3-finger clip with metallic gloss and with the marking
“piston side” on the steel supporting plate) and the outer brake pad (with the small black 3-finger clip).
❑ Observe the instructions for changing the pad ⇒ page 92
4 - Brake caliper
❑ removing:
– Remove the brake pads ⇒ page 94

– Use brake pedal load

– Unscrew brake hose from brake caliper
❑ Installing:
– Installing brake pads ⇒ page 94

– Screw the brake hose onto the brake caliper

– Remove brake pedal load

– Bleed brake system ⇒ page 198

❑ repairing ⇒ page 163
❑ Observe the instructions for changing the pad ⇒ page 92
5 - Guide bolt, 30 Nm Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
6 - Cap with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

❑ removing
7 - Tensioning sleeve
8 - Brake hose with supports, hollow screw and gasket rings
❑ must be replaced completely, do not dismantle
❑ Tightening torque: 35 Nm
❑ do not unscrew when replacing the brake pad
9 - Wheel hub with wheel bearing
❑ for vehicles with ABS the sensor ring is built into the wheel hub
❑ replace after each removal, is destroyed during removal
❑ removing and installing up to CW 11 2008 ⇒ axles, steering; Rep. gr. 40
❑ removing and installing as of CW 12 2008 ⇒ axles, steering; Rep. gr. 40
❑ Assignment ⇒ Electronic Catalogue of Original Parts
10 - Screw, 12 Nm
11 - Cover plate
12 - Wheel-bearing housing
13 - ABS wheel speed sensor
14 - Allan screw, 8 Nm
❑ for ABS speed sensor

1.3 Removing and installing brake pads and

floating caliper disc brake FS-III
Special tools and workshop equipment required

94 Rep. gr.46 - Brakes - mechanism

 Roomster 2006 ➤
Brake systems - Edition 02.2014

♦ Piston jig - MP9-403-

♦ Brake filling and bleeding device , e. g. -VAS 5234-
♦ Bleeding bottle (commercially available)
♦ Brake fluid ⇒ page 13
Observe the instructions for changing the pad ⇒ page 92 .
Removing:
– Remove wheel.

Note

♦ When removing mark the brake pads (inner, outer) you intend
to keep using. Install in the same location!
♦ Do not unscrew the brake hose from the brake caliper when
replacing the brake pad.

– Disconnect the plug connection for the brake pad wear indi‐
cator (where the vehicle is fitted with this).
– Remove caps -1-.

– Unscrew and remove the two guide bolts -arrows- from the
brake caliper.

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

1. Repairing front wheel brake 95

 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Remove the brake caliper -1- and secure with wire in such a
way that the weight of the brake caliper does not burden or
damage the brake hose.
– Remove brake pads -2- and -3- from the brake caliper.
Installing:

Note

Drain brake fluid from the brake fluid reservoir using a ventilation
bottle before pushing the piston back in.

Caution

Brake fluid is toxic and must never be sucked off by mouth.

Note

Use alcohol only to clean the brake caliper housing.

– Clean the brake caliper.

– Push piston back with piston jig - MP9-403- .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Insert the inner brake pad -1- (with the large 3-finger clip with
metallic gloss and with the marking “piston side” on the steel
supporting plate) on the piston.
– Insert the outer brake pad -2- (with the small black 3-finger
clip) into the brake caliper housing.

96 Rep. gr.46 - Brakes - mechanism

 Roomster 2006 ➤
Brake systems - Edition 02.2014

– First position the brake caliper with brake pads on the bottom
wheel bearing housing -arrow-.
– Tilt the brake caliper so that the guide bolts of the brake caliper
are flush with the threaded holes of the wheel-bearing hous‐
ing.
The bolts of the brake caliper -arrows- must only be inserted into
the brake caliper in such a way that the brake caliper can be tilted.

– Screw the brake caliper with both guide bolts -arrows- onto the
wheel bearing housing.
– Connect the plug connection for the brake pad wear indicator
(where the vehicle is fitted with this).
– Insert the caps of the guide bolts.
– Install wheel ⇒ Wheels, Tyres; Rep. gr. 44 .

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

♦ Observe the instructions for changing the pad ⇒ page 92

♦ After each brake pad replacement, forcefully apply the brake
pedal repeatedly to ensure the brake pads go into their normal
operating position.
♦ Check brake fluid level after replacing the brake pads, if nec‐
essary top up with brake fluid.

1. Repairing front wheel brake 97

 Roomster 2006 ➤
Brake systems - Edition 02.2014

Tightening torques:
Guide bolts of brake caliper to wheel-bearing housing 30 Nm
♦ Use new screws!

Brake line to brake caliper 35 Nm

Wheel bolts 120 Nm

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

98
 Roomster 2006 ➤
Brake systems - Edition 02.2014

1.4 Repairing front wheel brake - Floating

caliper disc brake C54
Special tools and workshop equipment required
♦ Piston jig - MP9-403-
♦ Brake pedal load , e.g. -V.A.G 1869/2-
♦ Brake filling and bleeding device , e. g. -VAS 5234-
♦ Bleeding bottle (commercially available)
♦ Brake fluid ⇒ page 13

Note

♦ Observe the instructions for changing the pad ⇒ page 92

♦ After replacing the brake pads, depress brake pedal firmly
several times when the vehicle is stationary to ensure the
brake pads are properly seated in their normal operating po‐
sition.
♦ Use the brake pedal load , e.g. -V.A.G 1869/2.- before remov‐
ing a brake caliper or separating a brake hose from the brake
caliper.
♦ Use a bleeding bottle, that only comes into contact with the
brake fluid, to drain brake fluid from the brake fluid reservoir.
Brake fluid is toxic and must never be sucked up by mouth!
♦ Already used brake fluid must never be used again.
♦ Tightening torque of the wheel screws 120 Nm.

Summary of components of front brake C54

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

99
 Roomster 2006 ➤
Brake systems - Edition 02.2014

1 - Brake disc
❑ Assignment, dimen‐
sions and wear limit
⇒ page 1
❑ the max. wheel run-out
is not marked
❑ approved brake disc
combinations without
marking and wheel hub
with marking
❑ with a fixing hole to the
wheel hub
❑ always replace axle-
wise
❑ for removing, first of all
unbolt brake caliper
complete from wheel
bearing housing
❑ Do not use force to sep‐
arate the brake discs
from the wheel hub, if
necessary use rust sol‐
vent; as you could oth‐
erwise damage the
brake discs
2 - Screw, 4 Nm
3 - Brake disc
❑ Assignment, dimen‐
sions and wear limit
⇒ page 1
❑ with a marking approx. 5
mm wide for marking the
maximum wheel run-out
❑ approved brake disc
combinations with
marking and wheel hub
without marking
❑ with 5 fixing holes to the wheel hub
❑ always replace axle-wise
❑ for removing, first of all unbolt brake caliper complete from wheel bearing housing
❑ Do not use force to separate the brake discs from the wheel hub, if necessary use rust solvent; as you
could otherwise damage the brake discs
4 - Pad retaining plate
❑ always replace when changing the brake pads
❑ brake pads contained in repair kit
❑ fit on before installing brake pads
5 - Brake pads
❑ with wear indicator (if the vehicle is fitted with this, only up to MY 2010)
– with a corresponding wear (limit: 2 to 3 mm) a warning light in the dash panel insert lights up (depending
on the vehicle equipment, only up to MY 2010)
❑ Thickness, wear limit ⇒ page 1 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ Inspect thickness ⇒ Maintenance ; Booklet unless
Roomster
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ always replace axle-wise
❑ to not unscrew the brake hose when replacing the brake pad
❑ removing and installing ⇒ page 102
❑ Observe the instructions for changing the pad ⇒ page 92

100
 Roomster 2006 ➤
Brake systems - Edition 02.2014

6 - Brake carrier
❑ is supplied as replacement part assembled with guide pin and protective caps as well as adequate
quantity of grease on guide pins
❑ if there is any damage to the protective caps or guide bolts fit a repair set (use the enclosed grease
packing to lubricate the guide bolts)
❑ also use grease packing for greasing the slot on the guide pin and brake caliper for attaching the pro‐
tective cap
7 - Collar
❑ contained in repair kit
❑ insert into the slot of the brake carrier and of the guide pin; grease the slot first using grease packing
from the repair kit
8 - Guide bolt
❑ contained in repair kit
9 - Heat shield
❑ always replace when changing the brake pads
❑ contained in repair kit
❑ insert into piston
Fitting position: insert plate at heat shield into the opening (slot) of the brake calliper

10 - Brake caliper
❑ Observe the instructions for changing the pad ⇒ page 92
❑ removing:
– Apply brake pedal depressor .

– Unscrew brake hose from brake caliper.

– Unbolt brake caliper from brake carrier.

❑ Installing:
– Bolt brake caliper onto brake carrier.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Screw the brake hose onto the brake caliper.

– Remove brake pedal load .

– Bleed brake system ⇒ page 198 .

❑ repairing ⇒ page 166
11 - Screw, 30 Nm
❑ replace after each removal
12 - Tensioning sleeve
13 - Brake hose with supports, hollow screw and gasket rings
❑ must be replaced completely, do not dismantle
❑ Tightening torque: 35 Nm
❑ do not unscrew when replacing the brake pad
14 - Screw, 125 Nm
❑ after the removal, clean the securing ribbing on the underside of the screw head
15 - Allan screw, 8 Nm
❑ for ABS speed sensor

101
 Roomster 2006 ➤
Brake systems - Edition 02.2014

16 - ABS wheel speed sensor

17 - Wheel-bearing housing
18 - Cover plate
19 - Screw, 12 Nm
20 - Wheel hub with wheel bearing
❑ with and without marking of the maximum wheel run-out
❑ one can combine a wheel hub without marking of the maximum wheel run-out with a brake disc with
marking of the maximum wheel run-out; the total wheel run-out of the floating caliper disc brake C54 will
not be reduced
❑ for vehicles with ABS the sensor ring is built into the wheel hub
❑ replace after each removal, is destroyed during removal
❑ removing and installing up to CW 11 2008 ⇒ axles, steering; Rep. gr. 40
❑ removing and installing as of CW 12 2008 ⇒ axles, steering; Rep. gr. 40
❑ Assignment ⇒ Electronic Catalogue of Original Parts

1.5 Removing and installing brake pads and

floating caliper disc brake C54
Special tools and workshop equipment required
♦ Piston jig - MP9-403-
♦ Brake filling and bleeding device , e. g. -VAS 5234-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ Bleeding bottle
unless authorised (commercially
by ŠKODA AUTO A. S. ŠKODAavailable)
AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ Brake fluid ⇒ page 13
Observe the instructions for changing the pad ⇒ page 92 .
Removing:
– Remove wheel.

Note

♦ When removing mark the brake pads you intend to keep using.
Install in the same location!
♦ Do not unscrew the brake hose when replacing the brake pad.
♦ If brake pads are changed, replace heat shield in the caliper
and pad retaining plates.

– Disconnect the plug connection for the brake pad wear indi‐
cator (where the vehicle is fitted with this).
– Detach brake line from fixture at wheel bearing housing.
– Unscrew bolt -1-.
– Remove brake caliper -2- and secure with wire in such a way
that the weight of the brake caliper does not pull on or damage
the brake hose.

102
 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Remove heat shield -2-.

– Take out brake pad -1-.
– Swivel brake pad -4- out to the side in -direction of arrow A-
and at the same time take out to the front in
-direction of arrow B-.
– Remove pad retaining plates -3- and -5-.
Installing:
Installation is carried out in the reverse order. Pay attention to the
following:

Note

Drain brake fluid from the brake fluid reservoir using a ventilation
bottle before pushing the piston back in.

Caution

Brake fluid is toxic and must never be sucked off by mouth.

Note

Use only methylated spirits for cleaning the brake caliper housing
and brake carrier.

– Clean the brake caliper.

– Clean contact surfaces for pad retaining plates at the brake
carrier, remove any corrosion present.

– Push piston backbywith

Protected piston
copyright. jigfor- private
Copying MP9-403- . purposes, in part or in whole, is not permitted
or commercial
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Install the heat shield.
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Fitting position: insert plate at heat shield into the opening (slot)
of the brake calliper.
– Install the pad retaining plate.
– Insert brake pads.
– Fit brake caliper to the brake carrier.
Do this while using new collar screws from the repair set.
– Attach brake line to fixture and secure with new clip.
– Connect the plug connection for the brake pad wear indicator
(where the vehicle is fitted with this).
– Install wheel ⇒ Wheels, Tyres; Rep. gr. 44 .

Note

♦ After each brake pad replacement, forcefully apply the brake

pedal repeatedly to ensure the brake pads go into their normal
operating position.
♦ Check brake fluid level after replacing the brake pads, if nec‐
essary top up with brake fluid.

103
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Tightening torques:
Brake caliper to brake carrier 30 Nm
♦ Use new screws!

Brake line to brake caliper 35 Nm

Wheel bolts 120 Nm

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

104
 Roomster 2006 ➤
Brake systems - Edition 02.2014

1.6 Repairing front wheel brake, brake cali‐

per FN3
Observe the instructions for changing the pad ⇒ page 92 .

Note

♦ After replacing the brake pads, depress brake pedal firmly several times when the vehicle is stationary to
ensure the brake pads are properly seated in their normal operating position.
♦ Use the brake filling and bleeding device e. g. -VAS 5234- to drain the brake fluid from the brake fluid
reservoir -VAS 5234- .
♦ Use the brake pedal load , e.g. -V.A.G 1869/2- before removing a brake caliper or separating a brake hose
from the brake caliper. -V.A.G 1869/2- .

1 - Brake disc
❑ Assignment, dimen‐
sions and wear limit
⇒ page 1
❑ always replace axle-
wise
❑ unscrew the brake cali‐
per before removing
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
2 - Screw, 4 Nm unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
3 - Brake pads
❑ Thickness, wear limit
⇒ page 1
❑ Inspect thickness
⇒ Maintenance ; Book‐
let Roomster
❑ always replace axle-
wise
❑ removing and installing
⇒ page 106
❑ Observe the instruc‐
tions for changing the
pad ⇒ page 92
4 - Retaining spring
❑ insert in both bores of
the brake caliper
5 - Brake carrier
❑ screwed onto the wheel-
bearing housing
6 - Brake caliper
❑ to not unscrew the brake
hose when replacing the
brake pad
❑ removing and installing
⇒ page 109
❑ repairing ⇒ page 167
❑ Observe the instructions for changing the pad ⇒ page 92
7 - Guide bolt, 30 Nm
8 - Cap
❑ remove

105
 Roomster 2006 ➤
Brake systems - Edition 02.2014

9 - Brake hose with banjo union and hollow screw, 35 Nm

10 - Screw, 124 Nm
❑ clean when using again
11 - Screw, 8 Nm
❑ for ABS speed sensor
12 - ABS wheel speed sensor
❑ clean the inner surface of the hole before inserting the sensor and brush over with a hot bolt paste - G
052 112 A3- .
13 - Wheel-bearing housing
❑ with bolted brake carrier
14 - Cover plate
15 - Screw, 12 Nm
16 - Wheel hub with wheel bearing
❑ Sensor ring for ABS is built into the wheel hub

1.7 Removing and installing brake pads for

brake caliper FN3
Special tools and workshop equipment required
♦ Piston jig - T10145-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Observeunless
the authorised
instructions forAUTO
by ŠKODA changing theAUTO
A. S. ŠKODA padA.⇒S.page
does not92 .
guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Removing:
When removing mark the brake pads you intend to keep using.
Install in the same location!
– Remove wheels.
– Lever up the retaining spring of the brake pads out of the brake
caliper -arrow- using a screwdriver and remove.

– Remove caps -arrows-.

106
 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Loosen and remove the two guide bolts -arrows- from the
brake caliper.
– Remove the brake caliper and secure with wire in such a way
that the weight of the brake caliper does not burden or damage
the brake line.
– Take out the brake pads from the brake caliper or from the
brake carrier.
– Clean the brake caliper, in particular the adhesive surface for
the brake pad must be free from adhesive residues and
grease.
Only use alcohol to clean the brake caliper.
Installing:
Drain the brake fluid from the brake fluid reservoir before the pis‐
ton is pushed with the piston jig into the cylinder.
Otherwise brake fluid can flow out and lead to damage if brake
fluid was added in the meantime.

– Push piston back with piston jig - T10145- -1-.

– Remove the protective foil from the supporting plate of the
outer brake pad.
– Place the outer brake pad on the brake carrier.
– Insert the inner brake pad with retaining spring into the brake
caliper (piston).
When installing the brake caliper make sure that the brake pad
does not stick to the brake caliper before reaching its correct in‐
stalled position.
Do not damage the surface to be glued.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Screw the brake caliper with both guide bolts to the brake car‐
rier.
– Insert both caps.
– Insert retaining spring in brake caliper.
– Attach the wheels.

Note

♦ After each brake pad replacement, forcefully apply the brake

pedal repeatedly to ensure the brake pads go into their normal
operating position.
♦ Check brake fluid level after replacing the brake pads.

107
 Roomster 2006 ➤
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Tightening torques:
Guide bolts to brake carrier 30 Nm
Brake line to brake caliper 35 Nm
Wheel bolts 120 Nm

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

108
 Roomster 2006 ➤
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1.8 Removing and installing brake caliper

FN3
Special tools and workshop equipment required
♦ Brake pedal load e.g. -V.A.G 1869/2-
Observe the instructions for changing the pad ⇒ page 92 .
Removing:

Note

The procedure applies only for the replacement or for the follow‐
ing repair work on the brake caliper.

– Remove wheels.
– Lever up the retaining spring of the brake pads out of the brake
caliper using a screwdriver and remove.
– Disconnect the plug connection for the brake pad wear indi‐
cator (where the vehicle is fitted with this).
– Attach the bleeder hose of the bleeding bottle onto the vent
valve of the brake caliper and then open then bleeder valve.
– Position brake pedal load e.g. -V.A.G 1869/2- .
– Close the vent valve and remove the bleeding bottle.
– Unscrew brake hose.
– Remove both caps out of the bushings of the brake caliper.
– Loosen and remove the two guide bolts from the brake caliper.
– Pull off brake caliper from brake carrier.
– Take out the brake pads from the brake caliper.
Installing:
• The piston is pushed back.
• The outside brake pad is fitted on the brake carrier.
– Insert the inner brake pad with retaining spring into the brake
caliper (piston).
When installing the brake caliper make sure that the brake pad
does not stick to the brake caliper before reaching its correct in‐
stalled position.
Do not damage the surface to be glued.
– Screw the brake caliper with both guide bolts to the brake car‐
rier.
– Insert both caps.
– Screw the brake hose onto the brake caliper.
– Remove brake pedal load e.g. -V.A.G 1869/2- .
– Insert retaining spring in brake caliper.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Connect the plug connection
unless authorised by for
ŠKODAtheAUTO
brake A. S.pad
ŠKODAwearAUTOindicator
A. S. does not guarantee or accept any liability
(where the vehiclewithisrespect
fittedtowith this).
the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Bleed brake system ⇒ page 198 .

– Attach the wheels.

109
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Note

♦ Forcefully apply the brake pedal repeatedly to ensure the

brake pads go into their normal operating position.
♦ Inspecting the brake fluid level.

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

110
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Tightening torques:
Guide bolts to brake carrier 30 Nm
Brake line to brake caliper 35 Nm
Wheel bolts 120 Nm

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

111
 Roomster 2006 ➤
Brake systems - Edition 02.2014

2 Repairing rear brake

⇒ “2.1 Replacing the brake shoes of the rear brake - Mounting
instructions”, page 112
⇒ “2.2 Removing and installing rear brake - Drum brake up to
44.2012”, page 112
⇒ “2.3 Repairing rear brake - Drum brake up to 44.2012”,
page 114
⇒ “2.4 Removing and installing brake shoes - Drum brake up to
44.2012”, page 116
⇒ “2.5 Removing and installing rear brake - Drum brake from
45.2012”, page 120
⇒ “2.6 Repairing rear brake - Drum brake from 45.2012”,
page 123
⇒ “2.7 Removing and installing brake shoes - Drum brake from
45.2012”, page 126
⇒ “2.8 Testing wheel-brake cylinder for tightness”, page 131
⇒ “2.9 Changing the brake pads of the rear wheel disc brake -
Mounting instructions”, page 131
⇒ “2.10 Removing and installing rear brake - Disc brake”,
page 131
⇒ “2.11 Removing and installing brake pads - Rear disc brake”,
page 133

2.1 Replacing the brake shoes of the rear

brake - Mounting instructions
When changing the brake shoes, pay attention to the following
points: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Check the protective collars
with respect ofcorrectness
to the the wheel-brake
of information incylinders.
this document. Copyright by ŠKODA AUTO A. S.�

Replace the wheel-brake cylinders if the protective collars are

damaged.
– Test wheel-brake cylinder for tightness ⇒ page 131 .
Replace the wheel-brake cylinder if leaking.
– Check if the pistons can be slightly pressed into the brake cal‐
iper.
If the pistons cannot be slightly pressed into the brake caliper:
– Replace the wheel-brake cylinder.

2.2 Removing and installing rear brake -

Drum brake up to 44.2012
Special tools and workshop equipment required
♦ Brake pedal load , e.g. -V.A.G 1869/2- .
♦ Disassembly wedge - 3409-
♦ Brake filling and bleeding device , e. g. -VAS 5234-
♦ Hook -3438-
♦ Brake fluid ⇒ page 13
♦ Solid lubricant paste - G 000 650-
♦ Anti-corrosion agent - AKR 322 000-

112
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Note

♦ Use brake pedal load , e. g. -V.A.G 1869/2- , before removing

a brake cylinder, a brake carrier or before separating a brake
line from the brake cylinder.
♦ Use a bleeding bottle, that only comes into contact with the
brake fluid, to drain brake fluid from the brake fluid reservoir.
Brake fluid is toxic and must never be sucked up by mouth!
♦ Already used brake fluid must never be used again.
♦ Generally tighten the brake line pipe screws to a tightening
torque of 14 Nm.
♦ After working on rear wheel brakes: Firmly depress brake ped‐
al several times with vehicle stationary so that the brake shoes
are properly seated in their normal operating position.
♦ Tightening torque of the wheel screws 120 Nm.

Summary of components of rear axle brake - drum brake

1 - Screw, 4 Nm
2 - Brake drum
❑ Brake drum diameter,
wear limit ⇒ page 1
❑ clean carefully, and
check for wear, dam‐
age, dimensional accu‐
racy and perfect brake
surface
❑ Thoroughly clean the Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
centering hole of the
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
drum before installing with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
and subsequently treat
it with approx. 0.5 g of
anti-corrosion agent -
AKR 322 000-
3 - Cap
❑ replace after each re‐
moval
❑ extracting and inserting
⇒ Axles, steering; Rep.
gr. 42
4 - Self-locking twelve-point
nut 70 Nm +40°
❑ replace after each re‐
moval
5 - Wheel hub with wheel bear‐
ing
❑ for vehicles with ABS
❑ Sensor ring for ABS is
built into the wheel hub
❑ wheel hub and wheel
bearing form one unit; it
does not need servicing
❑ The sensor ring for ABS
cannot be replaced indi‐
vidually
❑ removing and installing ⇒ Axles, steering; Rep. gr. 42

2. Repairing rear brake 113

 Roomster 2006 ➤
Brake systems - Edition 02.2014
❑ Assignment ⇒ Electronic Catalogue of Original Parts
❑ Before installing the brake drum, thoroughly clean the centering shoulder for the brake drum and sub‐
sequently treat it with approx. 0.5 g of anti-corrosion agent - AKR 322 000-
6 - Wheel hub with wheel bearing
❑ for vehicles without ABS
❑ wheel hub and wheel bearing form one unit; it does not need servicing
❑ removing and installing ⇒ Axles, steering; Rep. gr. 42
❑ Assignment ⇒ Electronic Catalogue of Original Parts
7 - Screw, 50 Nm + 60°
❑ replace after each removal
8 - Brake carrier with brake shoes
❑ repairing ⇒ page 114
9 - Welded axle
❑ Assignment ⇒ Electronic Catalogue of Original Parts
❑ The contact surface and the threaded holes for axle studs must be free from paint and dirt
❑ removing and installing ⇒ Axles, steering; Rep. gr. 42
10 - Axle stud
❑ Straightening work is prohibited
❑ Re-cutting the thread is not allowed!
❑ removing and installing ⇒ Axles, steering; Rep. gr. 42
11 - Screw, 8 Nm
12 - ABS wheel speed sensor
❑ only on vehicles with ABS
❑ clean the inner surfaces of the hole before inserting the sensor and grease with a solid lubricant paste -
G 052 112 A3-

Reset brake - Drum brake

– Use a screwdriver to push the wedge up through a hole for the
wheel screws in the brake drum.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
2.3 Repairing rear brake - Drum brake up to
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

44.2012
Special tools and workshop equipment required
♦ Brake pedal load , e.g. -V.A.G 1869/2- .
♦ Disassembly wedge - 3409-
♦ Brake filling and bleeding device , e. g. -VAS 5234-
♦ Hook -3438-
♦ Brake fluid ⇒ page 13
♦ Solid lubricant paste - G 000 650-

114
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Note

♦ Use brake pedal load , e. g. -V.A.G 1869/2- , before removing

a brake cylinder, a brake carrier or before separating a brake
line from the brake cylinder.
♦ Use a bleeding bottle, that only comes into contact with the
brake fluid, to drain brake fluid from the brake fluid reservoir.
Brake fluid is toxic and must never be sucked up by mouth!
♦ Already used brake fluid must never be used again.
♦ Generally tighten the brake line pipe screws to a tightening
torque of 14 Nm.
♦ After working on rear wheel brakes: Release hand brake,
press brake pedal forcefully several times with vehicle sta‐
tionary so that the brake pads are properly seated in their
normal operating position.
♦ Tightening torque of the wheel screws 120 Nm.

Summary of components of rear drum brake

1 - Spring plate
❑ To remove, push
against compression
spring and turn by 90°.
2 - Pressure spring
3 - Locating spring
4 - Pressure rod
❑ Grease the contact
points with solid lubri‐
cant paste - G 000 650-
5 - Wedge
❑ when removing and in‐
stalling the brake drum
push up through a hole
for the wheel screw (re‐
set brake) ⇒ page 114
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
6 - Wheel-brake cylinder
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ Observe the instruc‐
tions when replacing the
brake shoes
⇒ page 112
❑ test tightness
⇒ page 131
❑ Repairs not allowed
❑ Mounting instructions
⇒ page 112
❑ removing:
– Remove the brake shoe
⇒ page 116

– Use brake pedal load

– Unscrew the brake line

– Remove the wheel-brake cylinder

❑ Installing:

2. Repairing rear brake 115

 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Install the wheel-brake cylinder

– Screw on the brake line

– Remove brake pedal load

– Install the brake shoe ⇒ page 116

– Bleed brake system ⇒ page 198

7 - Allan screw, 8 Nm
8 - Straddle pin
9 - Brake carrier
10 - Plug
❑ remove to check brake pad thickness
11 - Sliding block
❑ Cover the whole contact surface of the brake shoe with solid lubricant paste - G 000 650-
12 - Brake shoe
❑ Observe the instructions when replacing the brake shoes ⇒ page 112
❑ removing and installing ⇒ page 116
❑ Minimum pad thickness without supporting shoe: ⇒ page 1
❑ Check the brake lining thickness ⇒ Maintenance ; Booklet Roomster
❑ Visual checking of the brake pad thickness through the inspection hole in the brake carrier
⇒ page 116 .
❑ always use equivalent pad quality per axle
❑ Brake pads can also be supplied without supporting shoe
13 - Tension spring
14 - Bottom retractor spring
❑ Grease the contact points with solid lubricant paste -Copying
Protected by copyright. G 000 650- or commercial purposes, in part or in whole, is not permitted
for private
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
15 - Top retractor spring with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

16 - Brake shoe with handbrake lever

❑ removing and installing ⇒ page 116
❑ Setting the handbrake ⇒ page 142

Checking the brake pad thickness through the inspection hole in

the brake carrier.
– Unclip cap -1- from the brake carrier-2-.
– Checking the brake pad thickness through the inspection hole
in the brake carrier.
Minimum pad thickness without supporting shoe (wear dimen‐
sion) ⇒ page 1 .

Note

The brake pads must not be soiled with brake fluid or grease.

2.4 Removing and installing brake shoes -

Drum brake up to 44.2012
Special tools and workshop equipment required

116
 Roomster 2006 ➤
Brake systems - Edition 02.2014

♦ Hook -3438-
♦ Solid lubricant paste - G 000 650-
Removing:
– Remove wheel.
– Remove the brake drum.
– Remove spring cap with pressure springs.
– Use a screwdriver to lever off the brake shoes from the bottom
support in the direction of the arrow.
– Unhook the retractor spring at the bottom.
– Unhook the hand-brake cable.
– Carefully guide the brake shoes out between the wheel hub
and the brake carrier.

– Clamp brake shoes in vice.

– Remove the tension spring -1- for wedge -2-.
– Unhook the retractor spring at the top -3- with hook -A-.

– Unhook the locating spring -1- with hook -A-.

– Remove the pressure rod -2- and the wedge -3- from the brake
shoe.
Installing:

– Grease the contact point of the pressure rod using solid lubri‐
cant Protected
paste -byGcopyright.
000 650- . for private or commercial purposes, in part or in whole, is not permitted
Copying
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Insert the locating
with respect to thespring -1-of in
correctness the brake
information in this shoe -2-Copyright
document. and position
by ŠKODA AUTO A. S.�
the brake shoe on the pressure rod -3-

2. Repairing rear brake 117

 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Hook locating spring -1- with hook -A- in the pressure rod -2-.
– Insert wedge -3-.

Note

Observe fitting location of wedge. The raised part of the wedge

-arrow- must remain visible during installation.

– Grease the contact point of the pressure rod using solid lubri‐
cant paste - G 000 650- .
– Insert the brake shoe with handbrake lever in the pressure rod.
– Hook on the retractor spring at the top -3- with hook -A-.
– Hook on the tension spring -1- for wedge -2-.
– Carefully guide the brake shoes in between the wheel hub and
the brake carrier.
– Position brake shoes on the brake cylinder pistons.
– Hook the handbrake cable onto the handbrake lever.
– Grease the contact points of the bottom retractor spring on the
brake shoe with solid lubricant paste - G 000 650- .
– Insert the bottom retractor spring and lift the brake shoe onto
the bottom bracket.
– Insert the pressure spring with spring cap.
– Install brake drum.
– Activate the foot pedal forcefully once; this causes the rear
wheel-brake to be adjusted.
– Setting the handbrake ⇒ page 142 .
– Install wheel ⇒ Wheels, Tyres; Rep. gr. 44 .

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

118
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Tightening torques:
Securing screw to brake drum 4 Nm
Wheel bolts 120 Nm

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

119
 Roomster 2006 ➤
Brake systems - Edition 02.2014

2.5 Removing and installing rear brake -

Drum brake from 45.2012
Special tools and workshop equipment required
♦ Brake pedal load , e.g. -V.A.G 1869/2-
♦ Brake filling and bleeding device , e. g. -VAS 5234-
♦ Bleeding bottle (commercially available)
♦ Brake fluid ⇒ page 13
♦ Anti-corrosion agent - AKR 322 000-

Note

♦ After replacing the wheel-brake cylinder, brake carrier and the

rear brake shoes, forcefully apply the brake pedal once to en‐
sure the brake shoes go into their normal operating position.
♦ Generally tighten the brake line pipe screws to a tightening
torque of 14 Nm.
♦ Use a bleeding bottle, that only comes into contact with the
brake fluid, to drain brake fluid from the brake fluid reservoir.
Brake fluid is toxic and must never be sucked up by mouth!
♦ Use brake pedal load , e. g. -V.A.G 1869/2- , before removing
a brake cylinder, a brake carrier or before separating a brake
line from the brake cylinder.
♦ Already used brake fluid must never be used again.
♦ Tightening torque of the wheel screws: 120 Nm.

Summary of components of rear axle brake - drum brake

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

120
 Roomster 2006 ➤
Brake systems - Edition 02.2014

1 - 4 Nm
2 - Brake drum
❑ Brake drum diameter,
wear limit ⇒ page 1
❑ Clean carefully and
check for wear, dam‐
age, dimensional accu‐
racy and flawless brake
surface.
❑ Thoroughly clean the
centering hole of the
drum before installing
and subsequently treat
it with approx. 0.5 g of
anti-corrosion agent -
AKR 322 000-

Note

The anti-corrosion agent - AKR 322

000- must not get into the threads of
the wheel screws!

3 - Cap
❑ replace after each re‐
moval
❑ extracting and inserting
⇒ Axles, steering; Rep.
gr. 42
4 - 12-point nut, self-locking
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ replace after eachwith re‐respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
moval ⇒ Axles, steer‐
ing; Rep. gr. 42
5 - Wheel hub with wheel bear‐
ing
❑ for vehicles with ABS
the sensor ring is built into the wheel hub
❑ must be replaced completely
❑ removing and installing ⇒ Axles, steering; Rep. gr. 42
❑ Assignment ⇒ Electronic Catalogue of Original Parts
❑ Before installing the brake drum, thoroughly clean the centering shoulder for the brake drum and sub‐
sequently treat it with approx. 0.5 g of anti-corrosion agent - AKR 322 000-

Note

The anti-corrosion agent - AKR 322

000- must not get into the threads of
the wheel screws!

6 - Screw
❑ Tightening torque ⇒ Axles, steering; Rep. gr. 42
❑ replace after each removal
7 - Brake carrier with brake shoes
❑ removing:
– Resetting brake ⇒ page 122 .

– Remove the brake drum.

– Remove wheel hub with wheel bearing ⇒ Axles, steering; Rep. gr. 42 .

121
 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Apply brake pedal load .

– Fit the bleeder hose of the bleeding bottle onto the vent valve of the wheel-brake cylinder.

– Open bleed valve.

– Shut the vent valve once the brake fluid flowed out.

– Unscrew the brake line.

– Remove brake carrier.

– Unhook the hand brake cable if necessary.

❑ Installing:
– Install brake carrier.
– Hook on the hand brake cable if necessary.

– Install wheel hub with wheel bearing ⇒ Axles, steering; Rep. gr. 42 .

– Screw on the brake line.

– Remove brake pedal load .

– Install brake drum.

– Bleed brake system ⇒ page 198 .

❑ Repairing ⇒ page 123 .
8 - Hand-brake cable
❑ Setting the hand-brake ⇒ page 142
9 - Axle stud
❑ removing and installing ⇒ Axles, steering; Rep. gr. 42
❑ Assignment ⇒ Electronic Catalogue of Original Parts
10 - Brake line
❑ Tightening torque of pipe screw: 14 Nm
11 - ABS wheel speed sensor
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
12 - Plug unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ for vehicles without ABS
❑ to plug the hole for the speed sensor in the axle stud
❑ Assignment ⇒ Electronic Catalogue of Original Parts
13 - Allan screw, 8 Nm
❑ for ABS speed sensor
14 - Axle beam
❑ Assignment ⇒ Electronic Catalogue of Original Parts

Reset brake - Drum brake

– Release the hand-brake.
– Remove storage compartment or arm rest ⇒ Body Work; Rep.
gr. 68 .

122
 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Release resetting nut -3- and unhook hand-brake cables -1-

from compensating clamp -2-.

– Press the handbrake lever through a hole for the wheel screw
using a screwdriver.

2.6 Repairing rear brake - Drum brake from

45.2012
Special tools and workshop equipment required
♦ Brake pedal load , e.g. -V.A.G 1869/2-
♦ Disassembly wedge - 3409-
♦ Brake filling and bleeding device , e. g. -VAS 5234-
♦ Hook (commercially available)
♦ Brake fluid ⇒ page 13 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Note

♦ Use brake pedal load , e. g. -V.A.G 1869/2- , before removing

a brake cylinder, a brake carrier or before separating a brake
line from the brake cylinder.
♦ Generally tighten the brake line pipe screws to a tightening
torque of 14 Nm.
♦ After working on rear wheel brakes: Release handbrake:
forcefully apply the foot brake repeatedly.

Assembly unit of rear drum brake

123
 Roomster 2006 ➤
Brake systems - Edition 02.2014

1 - Wheel brake cylinder

❑ Observe the instruc‐
tions when replacing the
brake shoes
⇒ page 112
❑ test tightness
⇒ page 131
❑ Repairs not allowed
❑ removing:
– Remove the brake
shoes ⇒ page 126 .

– Use brake pedal load .

– Fit the bleeder hose of

the bleeding bottle onto
the vent valve of the
wheel-brake cylinder.

– Open bleed valve.

– Shut the vent valve once

the brake fluid flowed
out.

– Unscrew the brake line.

– Remove wheel-brake
cylinder.
❑ Installing:
– Install wheel-brake cyl‐
inder.

– Screw on the brake line.

– Remove brake pedal

load .

– Install the brake shoes ⇒ page 126 .

– Bleed brake system ⇒ page 198 .

2 - Brake carrier
3 - Pin
4 - Screw, 10 Nm
5 - Ventilation valve cap
6 - Vent valve
7 - Plug
❑ remove to check brake pad thickness
8 - Top brake spring
❑ Grease the contact points with solid lubricant paste - G 000 650-
9 - Expansion rod
❑ with thermal clip
❑ with setting wheel and self-adjuster
❑ Fitting position ⇒ page 125

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

124
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Note

Grease the contact points with solid

lubricant paste - G 000 650-

10 - Brake shoe with handbrake lever

❑ removing and installing ⇒ page 126
❑ Setting the hand-brake ⇒ page 142
11 - Clamp
❑ for locking the brake shoe
❑ Fitting position ⇒ page 125
12 - Bottom return spring
❑ Grease the contact points with solid lubricant paste - G 000 650-
13 - Brake shoe
❑ removing and installing ⇒ page 126
❑ Minimum pad thickness without supporting shoe ⇒ page 1
❑ Check the brake lining thickness ⇒ Maintenance ; Booklet Roomster
❑ Visual checking of the brake pad thickness through the inspection hole in the brake carrier
⇒ page 125 .
❑ always replace axle-wise

Fitting position of securing clamp

The securing clamp must point with its closed part to the wheel
hub.

Fitting position of expansion rod

1 - Brake shoe
2 - Handbrake lever
3 - Expansion rod with thermal clip

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Thermal clip - bimetal strip must point towards the brake drum.
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Checking the brake pad thickness through the inspection hole in

the brake carrier.

125
 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Loosen the cap -1- from the brake carrier -2-.

– Checking the brake pad thickness through the inspection hole
in the brake carrier.
Minimum pad thickness without supporting shoe (wear dimen‐
sion) ⇒ page 1 .

Note

The brake pads must not be soiled with brake fluid or grease.

2.7 Removing and installing brake shoes -

Drum brake from 45.2012
Special tools and workshop equipment required
♦ Hook - 3438-
♦ Lifting device - T30114-
♦ Assembly pliers - T30115-
♦ Solid lubricant paste - G 000 650-
Removing:
– Remove wheel.
– Resetting brake ⇒ page 122 .
– Remove the brake drum.
– Return the handbrake lever -A- with hook - 3438- to the oper‐
ating position.

– Remove the bottom retractor spring with the hook - 3438- .

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

126
 Roomster 2006 ➤
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– Remove the securing clamp and the pin of the brake shoe
-in direction of arrow-.

– Carefully release the brake shoe and detach the expansion

rod -in direction of arrow B- from the brake shoe.

Caution

Do not cut through the rubber bowl for the wheel-brake cylinder
when handling the brake shoe.

– Detach the expansion rod -in direction of arrow A- from the

brake shoe with handbrake lever.

– Remove the top brake spring and the brake shoe.

– Unhook the hand-brake cable.
– Remove the securing clamp with the pin of the brake shoe with
handbrake lever.
– Remove brake shoe.
Installing:

– Grease the contact points -arrows- with solid lubricant paste -

G 000 650- .

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

127
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– Insert the brake shoe with handbrake lever and interlock the
securing clamp on the pin with the assembly device - T30114- .
– Note installation position ⇒ page 125 .

– Insert the top brake spring.

– Insert theProtected
pin and the fixing
by copyright. clamp
Copying fororthe
for private brakepurposes,
commercial shoe.in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Hook in the bottom retractor spring with the hook - 3438- .

– Carefully screw the expansion rod to its shortest dimension,
do not tighten.

Note

If the expansion rod is tightened too much, the self-adjuster

mechanism does no longer operate.

128
 Roomster 2006 ➤
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– Pull apart the brake shoes with assembly pliers - T30115- .

– First of all, position the expansion rod of the self-adjuster

-in direction of arrow A- on the brake shoe with handbrake
lever.
– Insert the lever for the self-adjuster into the recess of the sec‐
ond brake shoe -arrow B-.
– Note installation position ⇒ page 125 .

– Repeatedly pull apart the brake shoes using the assembly pli‐
ers - T30115- , so that the self-adjuster presets the distance
from the edges of the brake shoes with lining to the dimension
-a-.
a - 227.8 mm
– Clean the centring seat of the wheel hub for the brake drum
and subsequently treat it with anti-corrosion agent - AKR 322
000- .
– Clean the centring hole of the brake drum and subsequently
treat it with anti-corrosion agent - AKR 322 000- .

Note

The anti-corrosion agent - AKR 322 000- must not get into the
threads of the wheel screws!

– Install brake drum.

– Activate the brake pedal forcefully several times, so that the
rear brake is adjusted.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Setting the hand-brake ⇒topage
with respect 142 . of information in this document. Copyright by ŠKODA AUTO A. S.�
the correctness

– Attach the wheel.

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Tightening torques:
Securing screw to brake drum 4.5 Nm
Wheel bolts 120 Nm

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

130
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2.8 Testing wheel-brake cylinder for tight‐

ness

Note

♦ The tightness test is performed only visually without using any

tools and without removing the dust cap.
♦ The dust cap may get damaged in case of removal.
♦ Slight traces of grease in the area of the wheel-brake cylinder
do not point to a leakage. It is essentially assembly grease.

– Check the wheel-brake cylinder.

– If brake fluid drips out of the wheel-brake cylinder, the wheel-
brake cylinder must be replaced.

2.9 Changing the brake pads of the rear

wheel disc brake - Mounting instructions
When changing the pad, observe the following:
– Check protective collar of brake caliper piston.
Replace the protective collar if damaged.
When replacing the collar:
– Check the contact surfaces of the brake piston and the brake
caliper for any dirt (oxydation).
Carefully clean the piston as well as the brake caliper if dirty and
replace the sealing sleeve.
– Check the brake piston and the brake caliper (corrosion,
grooves on the outside of the cylinder surface), replace the
brake caliper completely if damaged.
For brake caliper piston, press into the initial position:
– Check if the piston can be slightly pressed into the brake cal‐
iper.
If the piston cannot be slightly pressed into the brake caliper:
– Check and clean the brake piston as well as the brake caliper,
replace sealing sleeve and protective collar.
Replace the brake caliper completely if damaged.

2.10 Removing and installing rear brake -

Disc brake
Special tools and workshop equipment required
♦ Brake filling and bleeding device , e. g. -VAS 5234-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
♦ Brake pedal load, e.g. - V.A.G. 1869/2-
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ Bleeding bottle (commercially available)
♦ Brake fluid ⇒ page 13

131
 Roomster 2006 ➤
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Note

♦ After brake pad replacement forcefully apply the brake pedal

repeatedly to ensure the brake pads go into their normal op‐
erating position.
♦ Generally tighten the brake line pipe screws to a tightening
torque of 14 Nm.
♦ Before removing a brake caliper or separating a brake hose
from the brake caliper, the brake pedal must be locked; e.g.
with brake pedal load - V.A.G 1869/2- .
♦ Already used brake fluid must never be used again.
♦ Tightening torque of the wheel screws 120 Nm.

Summary of components of rear axle brake - rear disc brake

1 - Screw, 4 Nm
2 - Brake disc
❑ Thickness, wear limit
⇒ page 1
❑ if worn replace axle-
wise
3 - Cap
❑ detach and insert ⇒
Axles, steering; Rep. gr.
42
4 - Self-locking twelve-point Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
nut 70 Nm +40° with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ replace after each re‐
moval
5 - Wheel hub with wheel bear‐
ing
❑ Sensor ring for ABS is
built into the wheel hub
❑ replace after each re‐
moval
❑ must be replaced com‐
pletely
❑ removing and installing
⇒ Axles, steering; Rep.
gr. 42
6 - Screw, 30 Nm + 90°
7 - Cover plate
8 - Axle stud
9 - Hand-brake cable
❑ removing and installing
⇒ page 139
❑ Setting the hand-brake
⇒ page 142
10 - Axle beam
11 - ABS wheel speed sensor
❑ clean the inner surfaces of the hole before inserting the sensor and grease with a solid lubricant paste -
G 052 112 A3-

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12 - Screw, 8 Nm
13 - Screw, 30Nm + 30°
❑ replace after each removal
14 - Brake carrier with guide bolts and protective caps
❑ must be assembled with sufficient grease on the guide bolt, supplied as a spare part
❑ they must be replaced completely if there is any damage to the protective caps or guide bolts; use the
enclosed grease packing to lubricate the guide bolts
❑ Observe the instructions for changing the pad ⇒ page 131
15 - Brake hose with banjo union and hollow screw
❑ cannot be disassembled, must be fully replaced
❑ Tightening torque of hollow screw: 38 Nm
❑ do not unscrew the brake hose when replacing the brake pad
16 - Self-locking screw, 35 Nm
❑ replace after each removal
17 - Brake caliper
❑ to not unscrew the brake hose when replacing the brake pad
❑ removing and installing ⇒ Axles, steering; Rep. gr. 42
❑ repairing ⇒ page 171
18 - Brake pads
❑ Thickness, wear limit ⇒ page 1
❑ Inspect thickness ⇒ Maintenance ; Booklet Roomster
❑ always replace axle-wise
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ removing and installing ⇒ page 133
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

❑ Observe the instructions for changing the pad ⇒ page 131

19 - Pad retaining spring
❑ always replace when changing the brake pads

2.11 Removing and installing brake pads -

Rear disc brake
Special tools and workshop equipment required
♦ Brake filling and bleeding device , e. g. -VAS 5234-
♦ Resetting tool - T10165-
♦ Bleeding bottle (commercially available)
♦ Brake fluid ⇒ page 13

Note

♦ When removing mark the brake pads you intend to keep using.
Install in the same location, as otherwise this may cause un‐
even braking!
♦ Do not unscrew the brake hose when replacing the brake pad.

Removing:
– Put hand-brake back.
– Remove storage compartment or arm rest of the centre con‐
sole ⇒ Body Work; Rep. gr. 68 .

133
 Roomster 2006 ➤
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– Release adjusting nut -3- and thus release the hand-brake

cables.
– Remove wheels.

– Lever out the clip -1- using a screwdriver and remove towards
the bottom or slacken the spring bushing for the hand-brake
cable from the bracket on the brake caliper (depending on the
version).
– Push the hand-brake lever -2- in the direction of the arrow and
unhook the hand-brake cable -3-.

– Unscrew the fixing screws of the brake carrier while counter‐

holding the guide bolts.
– Remove the brake caliper and secure with wire in such a way
that the weight of the brake caliper does not burden or damage
the brake line.

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

134
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– Remove the brake pads and pad retaining springs -arrows-.

Note

Only use alcohol to clean the brake caliper.

– Clean the brake caliper housing, in particular the adhesive

surface for the brake pad must be free from adhesive residues
and grease.
Installing:

Note

Before inserting new brake pads, press piston with resetting tool
- T10165- into the brake caliper. Drain the brake fluid from the
brake fluid reservoir using a ventilation bottle before pushing
back.

WARNING

Brake fluid is toxic and must never be sucked into your mouth
through a hose.

– Press the piston by turning the knurled wheel of the resetting

tool - T10165- into the brake caliper. At the same time do not
damage the protective cap.
– Use special tool - T10165/1- for assembling.
Use open-jawed spanner on a provided spanner surface -A- if the
piston is difficult to move.

Note

When resetting the piston with a resetting tool the automatic pis‐
ton setting in the brake caliper is destroyed.

– Install the new brake pads and pad retaining springs

-arrows- in the brake carrier.
– Remove the protective foil from the supporting plate of the
brake pad.

Note

There are four self-locking screws in the repair set, which must
be fitted. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

135
 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Secure the brake caliper using new self-locking screws. Hold

the guide bolts while tightening the screws.

– Install the clip -1- or clip the spring bushing into the bracket on
the brake caliper (depending on the version).
– Push the hand-brake lever -2- in the direction of the arrow and
hook on the hand-brake cable -3-.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Tighten adjusting nut for hand-brake -3-unless
slightly.
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Note

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

– Depress brake pedal firmly several times when the vehicle is

stationary.
– Setting the hand-brake ⇒ page 142 .
– Install storage compartment or armrest of the centre console
⇒ Body Work; Rep. gr. 68 .
– Install wheels ⇒ Wheels, Tyres; Rep. gr. 44 .

Note

Check brake fluid level after replacing the brake pads, if neces‐
sary top up with brake fluid.

136
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Tightening torques:
self-locking screws to brake carrier 35 Nm
♦ Use new screws!

Wheel bolts 120 Nm

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

137
 Roomster 2006 ➤
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3 Handbrake
⇒ “3.1 Assembly overview of the handbrake”, page 138
⇒ “3.2 Removing and installing the hand-brake cable”,
page 139
⇒ “3.3 Setting the hand-brake”, page 142

3.1 Assembly overview of the handbrake

1 - Handbrake lever
❑ Removing the centre
console ⇒ Body Work;
Rep. gr. 68
❑ Assignment ⇒ Electron‐
ic Catalogue of Original
Parts
2 - Cover
❑ removing:
– Press down the catch
pegs at the bottom of the
trim panel with a small
screwdriver and pull off
the trim towards the
front.
❑ Installing:
– Slide the trim panel until
the catch peg catches
onto the hand-brake lev‐
er. Check trim panel
catch.
❑ Assignment ⇒ Electron‐
ic Catalogue of Original
Parts
3 - Compensating clamp
4 - Adjusting nut
❑ Setting the hand-brake
⇒ page 142
5 - Grommet
❑ removing:
– Pull hand-brake cable
from guide tube.

– Release grommet.

– Pull grommet from guide tube.

❑ Installing:
Installation is carried out in the reverse order. After installing make sure the grommet fits correctly in the
body recess.

6 - Right guide tube

❑ for hand-brake cable
7 - Left guide tube
❑ for hand-brake cable

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

138
 Roomster 2006 ➤
Brake systems - Edition 02.2014

8 - Hand-brake cable
❑ removing and installing ⇒ page 139
9 - Hand-brake lever support
❑ welded to the body tunnel
10 - Switch for hand-brake control - F9-
❑ clipped onto hand-brake lever
❑ replace if defective
11 - Self-locking nut, 20 Nm + 90°
❑ replace after each removal

3.2 Removing and installing the hand-brake

cable
Removing:
– Release the hand-brake.
– Remove storage compartment or arm rest ⇒ Body Work; Rep.
gr. 68 .
– Release resetting nut -3- and unhook hand-brake cables -1-
from compensating clamp -2-.
– Remove wheel.
– Raise vehicle.

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

– Unclip the hand-brake cable out of the clips on the axle body
and body -arrows-.
Vehicles with drum brakes
– Remove the brake drum ⇒ page 116 .
– Unhook the hand-brake cable at the hand-brake lever.
– Pull hand-brake cable out of brake carrier.

Vehicles with disc brakes

– Lever out the clip -1- using a screwdriver and remove towards
the bottom or slacken the spring bushing for the hand-brake
cable from the bracket on the brake caliper (depending on the
version).
– Press the hand-brake lever -2- in the -direction of the arrow-
and while doing so unhook the hand-brake cable -3-.
Continued for all vehicles

3. Handbrake 139
 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Pull hand-brake cable -2- in -the direction of the arrow- out of

the guide tube -1-.
Installing:
Installation is carried out in the reverse order.

Note

When installing the hand brake cables, pay attention to the fitting
position.

Fitting position of the hand-brake cables

Note

Fitting position of the hand-brake cables is identical on vehicles

with drum or disc brake (only version with drum brake is shown).

– The hand-brake cables must be clipped in.

– The clamping ring -arrow A- at the hand-brake cable must rest

in the centre of the clip -arrow B-.

Note

Before setting the hand-brake, slightly pretension the hand-brake

cable with the adjusting nut at the compensation clamp.

– Setting the hand-brake:

Vehicles with disc brakes ⇒ page 143 .
Vehicles with drum brakes ⇒ page 142 .

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

140
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Tightening torque:
Wheel bolts 120 Nm

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

141
 Roomster 2006 ➤
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3.3 Setting the hand-brake

3.3.1 Setting the hand-brake - drum brake

Note

♦ Resetting of the hand-brake is not required after resetting of

the rear brake due to automatic resetting of the rear wheel-
brake.
♦ Resetting is required after replacing the hand-brake cable, the
brake carrier or the brake pads/brake shoes or brake drum.

– Remove storage compartment or arm rest ⇒ Body Work; Rep.

gr. 68 .
– Release hand-brake (hand brake lever in rest position).
– Forcefully apply the foot brake repeatedly.
– Pull the handbrake on and release it three times.
This sets the components into position.
– Put the hand-brake lever into the 1st catch position (after being
in the release position).
– Tighten adjusting nut -arrow- until both wheels are hard to turn
by hand.

Note

The adjusting nut -arrow A- must be screwed over the end of the
tension rod (self-locking effect).

– Release hand-brake and check whether both wheels rotate

freely, if necessary release adjusting nut slightly.
– Put the hand-brake lever into the 4th catch position (after being
in the release position).
No wheel should be rotatable; tighten the adjusting nut if nec‐
essary.
– Release hand-brake and check whether both wheels rotate
freely, if necessary release adjusting nut slightly.
– Put the hand-brake lever into the 1st catch position and re‐
lease the hand-brake.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
The hand-brake must withautomatically return
respect to the correctness into theinrelease
of information po‐Copyright by ŠKODA AUTO A. S.�
this document.
sition below the 1st catch.
– Install storage compartment or arm rest ⇒ Body Work; Rep.
gr. 68 .

142
 Roomster 2006 ➤
Brake systems - Edition 02.2014

3.3.2 Setting the hand-brake - disc brake

Note

♦ Resetting of the hand-brake is not required after resetting of

the rear brake due to automatic resetting of the rear wheel-
brake.
♦ Resetting is required after replacing the handbrake cable, the
brake caliper, the brake pads or the brake discs.
♦ The brake system must be ventilated and the brake pedal fully
functional.

– Remove storage compartment or arm rest ⇒ Body Work; Rep.

gr. 68 .
– Release hand-brake (hand brake lever in rest position).
– Forcefully apply the foot brake repeatedly.
– Tighten adjusting nut -A- so far that the levers -B- rise from the
stops on the brake calipers.

Note

The adjusting nut -arrow A- must be screwed over the end of the
tension rod (self-locking effect).

– Check distance -a- between the lever and stop on the left and
right brake caliper using feeler gauges.
With the hand-brake released the distance -a- (between the lever
and the stop) on the left and right brake caliper must not be less
than or exceed a minimum of 1 mm and a maximum of 4mm. The
maximum distance of 3 mm on a brake must not be exceeded.
– Pull the handbrake on and release it three times. This sets the
components into position.
– Release the hand-brake and check whether the two wheels
turn freely, release the adjusting nut slightly and check dis‐
tance -a- again if necessary.
– Install storage compartment or arm rest ⇒ Body Work; Rep.
gr. 68 .

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

143
 Roomster 2006 ➤
Brake systems - Edition 02.2014

4 Foot Controls, Brake Pedal

⇒ “4.1 Summary of components of foot controls, brake pedal up
to MY 2010”, page 144
⇒ “4.2 Setting, removing and installing the brake light switch F
and brake pedal switch F47 up to MY 2010”, page 146
⇒ “4.3 Separating the brake pedal from the brake servo unit and
clipping up to MY 2010”, page 146
⇒ “4.4 Removing and installing the foot controls up to MY 2010 -
left-hand drive”, page 147
⇒ “4.5 Removing and installing the pedals up to MY 2010 - left-
hand drive”, page 151
⇒ “4.6 Removing and installing the pedals up to MY 2010 - right-
hand drive”, page 154
⇒ “4.7 Summary of components: Brake pedal from MY 2011 - left-
hand drive”, page 157
⇒ “4.8 Separating the brake pedal from the brake servo unit and
clipping as of MY 2011”, page 157
⇒ “4.9 Removing and installing
Protected the
by copyright. footforcontrols
Copying from MYpurposes,
private or commercial 2011 in- part or in whole, is not permitted
left-hand drive”, page
unless 158
authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
⇒ “4.10 Removing and installing the brake pedal from MY 2011 -
left-hand drive”, page 159
⇒ “4.11 Summary of components: Brake pedal from MY 2011 -
right-hand drive”, page 159
⇒ “4.12 Removing and installing the foot controls from MY 2011
- right-hand drive”, page 161
⇒ “4.13 Removing and installing the brake pedals from MY 2011
- right-hand drive”, page 161

4.1 Summary of components of foot controls, brake pedal up to MY 2010

Caution

The pedal travel must not be shortened by additional floor cov‐

erings.

Note

♦ Replace self-locking nuts each time they are removed.

♦ Before assembling the brake light switch grease the contact surface of the pedal tappet with polycarbamide
grease - G 052 142 A2- .

144
 Roomster 2006 ➤
Brake systems - Edition 02.2014

1 - Bearing bracket
❑ for foot controls
❑ Crash strut cannot be
removed, as it is welded
to bracket
❑ removing and installing
⇒ page 147
2 - Screw
3 - Self-locking nuts, 25 Nm
❑ replace after each re‐
moval
❑ 4 pieces for securing the
brake servo unit to the
bracket
❑ 2 pieces for securing the
bracket to the assembly
plate
4 - Brake light switch
❑ before assembling the
brake light switch clip
brake pedal to the pres‐
sure rod of the brake
servo unit
❑ the brake light switch
may only be installed
once to ensure that it
has an adequately tightProtected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
fit unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ Setting, removing and
installing the brake light
switch ⇒ page 146
❑ Inspecting proper oper‐
ation of the brake light
⇒ page 146
❑ Assignment ⇒ Electron‐
ic Catalogue of Original Parts
5 - Accelerator pedal with accelerator pedal position sender - G79- and - G185-
❑ Removing and Installing ⇒ Engine; Rep. gr. 20
6 - Brake pedal
❑ removing and installing ⇒ page 151
7 - Bushing
8 - Cap
9 - Bearing bolt
10 - Self-locking nut, 25 Nm
❑ replace after each removal
11 - Brake servo unit
❑ removing and installing ⇒ page 173
❑ Assignment ⇒ Electronic Catalogue of Original Parts
12 - Bulkhead plenum chamber
13 - Support of foot controls
❑ Part of the central pipe ⇒ axles, steering; Rep. gr. 48

4. Foot Controls, Brake Pedal 145

 Roomster 2006 ➤
Brake systems - Edition 02.2014

4.2 Setting, removing and installing the

brake light switch - F- and brake pedal
switch - F47- up to MY 2010
Special tools and workshop equipment required
♦ Polycarbamide grease - G 052 142 A2-

Note

The brake light switch must be removed for setting.

– Remove the storage area on the driver's side ⇒ Body Work;

Rep. gr. 70 .
– Unplug connector from brake light switch.
– Turn brake light switch -1- 45° to the left and remove from
bracket -2-.

Note

♦ The brake light switch may only be installed once to ensure

that it has an adequately tight fit.
♦ Carry out assembly of the brake light switch after clipping the
brake pedal with the brake servo unit ⇒ page 146 .
♦ Before assembling the brake light switch grease the contact
surface of the pedal tappet with polycarbamide grease -
G 052 142 A2- .

Pull the brake light switch tappet out completely up to its stop
before assembly since it will be automatically adjusted and set
during assembly.
– Guide the brake light switch through in the assembly opening,
press itProtected
against the brake pedal and install by turning it 45° to
by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
the right.
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Brake pedal always remains in the off position in this case (not
actuated).
– After installing the brake light switch, check whether brake
pedal is in the end position (release position).
– Mount plug on brake light switch.
– Checking the function of the brake light switch:
Actuate brake pedal ⇒ brake lights must light up.
Release brake pedal ⇒ brake lights must go out.
– Install the storage area on the driver's side ⇒ Body Work; Rep.
gr. 70 .

4.3 Separating the brake pedal from the

brake servo unit and clipping up to MY
2010
Special tools and workshop equipment required
♦ Release tool - T10159A-

146
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Separating the brake pedal from the brake servo unit

– Remove the storage area on the driver's side ⇒ Body Work;
Rep. gr. 70 .
– Remove brake light switch ⇒ page 146 .

Note

The fig. shows the separation of the brake pedal from the brake
servo unit with the foot controls removed for clarity.

– Press brake pedal -1- towards the brake servo unit and hold
in position.
– Insert release tool - T10159A- and pull towards the driver's
seat while counterholding the brake pedal. (At this moment the
pedal must not move backwards.)
This causes the retaining lugs -3- of the support to be pressed
off the spherical head of the push rod -2-.
– Pull the release tool and brake pedal jointly towards the driv‐
er's seat. (This causes the brake pedal to be drawn off the ball
knob of the pressure rod).
Clipping the brake pedal onto the brake servo unit

– Hold the spherical head of the pressure rod -2- in front of the
support and press the brake pedal -1- towards the brake servo
unit so that the spherical head locks audibly into place.
3 - Bearing bracket
– Setting and installing the brake light switch ⇒ page 146 .
– Install the storage area on the driver's side ⇒ Body Work; Rep.
gr. 70 .
– Inspecting proper operation of the brake light ⇒ page 146 .

4.4 Removing and installing the foot con‐

trols up to MY 2010 - left-hand drive
Special
Protected bytools and
copyright. workshop
Copying for privateequipment required
or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
♦ with
Vehicle diagnosis, measurement and information system -
respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

VAS-
♦ Release tool - T10159A-
Removing:
– Disconnect battery ⇒ Electrical System; Rep. gr. 27 .
– Remove the storage area on the driver's side ⇒ Body Work;
Rep. gr. 70 .

4. Foot Controls, Brake Pedal 147

 Roomster 2006 ➤
Brake systems - Edition 02.2014

Vehicles without air conditioning system

– Removing the left footwell vent ⇒ Heating, Air Conditioning;
Rep. gr. 80 .
Vehicles with air conditioning
– Removing the left footwell vent ⇒ Heating, Air Conditioning;
Rep. gr. 87 .
Vehicles with Convenience system central control unit - J393-
– Removing the convenience system central control unit - J393-
⇒ Body Work; Rep. gr. 70 .
Continued for all vehicles
– Unscrew plastic nuts -1-.
– Remove cover -2-.
– Remove brake light switch ⇒ page 146 .
– Pull out plug of accelerator pedal position sender - G79- .
– Separate brake pedal from brake servo ⇒ page 146 .

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Unscrew foot control securing nuts -arrows-.
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
The top foot control securing nut is not visible in the figure. It is
located at the bulkhead above the foot controls
⇒ Item 3 (page 145) .
– Remove accelerator pedal from foot controls (3 screws).
– Remove foot pedal cluster.
Installing:
– Insert foot controls.
– Install accelerator pedal at foot controls (3 screws).

148
 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Screw on foot control securing nuts and tighten.

The top foot control securing nut is not visible in the figure. It
is located at the bulkhead above the foot controls
⇒ Item 3 (page 145) .
– Clip the brake pedal onto the brake servo unit ⇒ page 146 .
– Mount the plug of the accelerator pedal position sender -
G79- .
– Setting and installing the brake light switch ⇒ page 146 .
– Install the storage area on the driver's side ⇒ Body Work; Rep.
gr. 70 .

– Install cover -2- and tighten plastic nuts -1-.

– Connect battery ⇒ Electrical System; Rep. gr. 27 .
– Perform a vehicle system test using the vehicle diagnosis,
measurement and information system - VAS- ⇒ page 20 .

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

4. Foot Controls, Brake Pedal 149

 Roomster 2006 ➤
Brake systems - Edition 02.2014

Tightening torques:
Foot controls on brake servo unit and on bulkhead 25 Nm
♦ Use new nuts!

Accelerator pedal on foot controls 9 Nm

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

150
 Roomster 2006 ➤
Brake systems - Edition 02.2014

4.5 Removing and installing the pedals up

to MY 2010 - left-hand drive
Special tools and workshop equipment required
♦ Vehicle diagnosis, measurement and information system -
VAS-
♦ Release tool - T10159A-
♦ Internal extractor (10.0...14.0 mm) - Kukko 21/02-
♦ Polycarbamide grease - G 052142 A2-
Removing:
– Remove the storage area on the driver's side ⇒ Body Work;
Rep. gr. 70 .
Vehicles without air conditioning system
– Removing the left footwell vent ⇒ Heating, Air Conditioning;
Rep. gr. 80 .
Vehicles with air conditioning
– Removing the left footwell vent ⇒ Heating, Air Conditioning;
Rep. gr. 87 .
Vehicles with Convenience system central control unit - J393-
– Removing the convenience system central control unit - J393-
⇒ Body Work; Rep. gr.authorised
70 . by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Continued for all vehicles
– Remove brake light switch ⇒ page 146 .
– Pull out plug of accelerator pedal position sender - G79- .
– Separate brake pedal from brake servo ⇒ page 146 .
– Unscrew nut -1-.
2 - Brake pedal

Note

In the Fig. screw for bearing bolt is covered by the bracket.

– Release screw for bearing bolt -arrow-.

– Remove brake pedal -2-.

151
 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Pull bearing bolt -1- out of the casing tube -3- of the brake
pedal.

Note

Replace all removed bushings.

– Insert and tension interior extractor -Kukko 21/02- on the

bushing -2-.
– Pull out bushing by hand from the casing tube.
Installing:
Installation is carried out in the reverse order.

Note

Do not tilt bushings when installing.

– Insert new bushings in the brake pedal if they were removed.

Press in bushings up to stop.
– Grease bearing points of the brake pedal (bearing bolts and
bushings) with polycarbamide grease - G 052 142 A2- .
– Setting and installing the brake light switch ⇒ page 146 .
– Perform a vehicle system test using the vehicle diagnosis,
measurement and information system - VAS- ⇒ page 20 .

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

152
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Tightening torque:
Brake pedal to bracket 25 Nm
♦ Use new nuts!

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

153
 Roomster 2006 ➤
Brake systems - Edition 02.2014

4.6 Removing and installing the pedals up

to MY 2010 - right-hand drive
Special tools and workshop equipment required
♦ Vehicle diagnosis, measurement and information system -
VAS-
♦ Release tool - T10159A-
♦ Internal extractor (10.0...14.0 mm) - Kukko 21/02-
♦ Polycarbamide grease - G 052142 A2-
Removing:
– Remove the storage area on the driver's side ⇒ Body Work;
Rep. gr. 70 .
Vehicles without air conditioning system
– Remove right footwell vent ⇒ Heating, Air Conditioning; Rep.
gr. 80 .
Vehicles with air conditioning
– Remove right footwell vent ⇒ Heating, Air Conditioning; Rep.
gr. 87 .
Continued for all vehicles
– Remove brake light switch ⇒ page 146 .
– Pull out plug of accelerator pedal position sender - G79- .
– Separate brake pedal from brake servo ⇒ page 146 .
– Unscrew nut -1-.
2 - Brake pedal

Note

In the Fig. screw for bearing bolt is covered by the bracket.

– Release screw for bearing bolt -arrow-.

– Remove brake pedal -2-.

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

154
 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Pull bearing bolt -1- out of the casing tube -3- of the brake
pedal.

Note

Replace all removed bushings.

– Insert and tension interior extractor -Kukko 21/02- on the

bushing -2-.
– Pull out bushing by hand from the casing tube.
Installing:
Installation is carried out in the reverse order.

Note

Do not tilt bushings when installing.

– Insert new bushings in the brake pedal if they were removed.

Press in bushings up to stop.
– Grease bearing points of the brake pedal (bearing bolts and
bushings) with polycarbamide grease - G 052 142 A2- .
– Setting and installing the brake light switch ⇒ page 146 .
– Perform a vehicle system test using the vehicle diagnosis,
measurement and information system - VAS- ⇒ page 20 .

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

155
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Tightening torque:
Brake pedal to bracket 25 Nm
♦ Use new nuts!

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

156
 Roomster 2006 ➤
Brake systems - Edition 02.2014

4.7 Summary of components: Brake pedal

from MY 2011 - left-hand drive

Caution

The travel of the brake pedal must not be shortened by addi‐

tional foot mats.

Grease all bearing surfaces with polycarbamide grease -G 052

142 A2- before assembly.
The brake light switch is located on the master brake cylinder.

1 - Foot controls
❑ removing and installing
⇒ page 158
2 - Self-locking nut, 25 Nm
❑ replace after each re‐
moval
3 - Bushing
4 - Brake pedal
5 - Cap
6 - Bearing shell
7 - Clip
❑ for the spherical head of
the pressure rod of the
brake servo unit
8 - Bearing bolt
❑ must only be fitted once,
because the tabs break
off when removing
9 - Bushing

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

4.8 Separating the brake pedal from the

brake servo unit and clipping as of MY
2011
Special tools and workshop equipment required
♦ Release tool - T10159A-

157
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Separate
– Press the brake pedal towards the brake servo unit and hold
it in position.
2 - Pressure rod
3 - Retaining lugs
– Insert release tool - T10159A- and pull it in the direction of the
driver's seat while counterholding the brake pedal (the pedal
must not move backwards during this operation). This causes
the retaining lugs -3- of the support to be pressed off the
spherical head of the push rod -2-.
The fig. shows the separation of the brake pedal from the brake
servo unit with the foot controls removed for clarity.
– Pull the release tool - T10159A- and brake pedal jointly to‐
wards the driver's seat. (This causes the brake pedal to be
pulled off the spherical head of the pressure rod).
Assembling together:

– Hold the spherical head of the push rod in front of the support
and press the brake pedal towards the brake servo unit until
the spherical head locks audibly into place.
– Check that it is correctly locked in place by briefly pulling on
the brake pedal.

4.9 Removing and installing the foot con‐

trols from MY 2011 - left-hand driveCopying for private or commercial purposes, in part or in whole, is not permitted
Protected by copyright.
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Removing:
– Remove cover of fuse box -1-.
– Unscrew the fuse box and lay it to the side.
– Remove crash strut ⇒ axles, steering; Rep. gr. 48 .
Vehicles without air conditioning system
– Remove the footwell vent ⇒ Heating, Air Conditioning; Rep.
gr. 80 .
For vehicles with air conditioning
– Remove the footwell vent ⇒ Heating, Air Conditioning; Rep.
gr. 87 .
– Disconnect the plug connection from the accelerator pedal
position sender.
– Remove the accelerator pedal ⇒ Relevant engine; Rep. gr.
20 .
– Separating the brake pedal from the brake servo unit
⇒ page 157 .

158
 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Unscrew the nuts -arrows- on the foot controls.

– Remove the foot controls.
Installing:
Installation is carried out in the reverse order.
– Clip the brake pedal onto the brake servo unit ⇒ page 157 .

4.10 Removing and installing the brake pedal

from MY 2011 - left-hand drive
Removing:
– Remove the foot controls ⇒ page 158 .
– Turn the bearing axle to the left in -direction of arrow- using a
10 mm socket wrench, while doing so the tabs break off
-arrows 1-.
– Pull out bearingunless
bolt.authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted

with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Remove brake pedal.
Installing:
Installation is carried out in the reverse order.

– Insert the bearing axle and turn clockwise in

-direction of arrow- using a 10 mm socket wrench until the tabs
-arrows 2- rest against the stop.
– Install the foot controls ⇒ page 158 .
– Clip the brake pedal onto the brake servo unit ⇒ page 157 .

4.11 Summary of components: Brake pedal from MY 2011 - right-hand drive

Caution

The pedal travel must not be shortened by additional floor cov‐

erings.

159
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Note

♦ Replace self-locking nuts each time they are removed.

♦ Grease all bearing surfaces with polycarbamide grease - G 052 142 A2- before assembly.
♦ The brake light switch is located on the master brake cylinder.

1 - Screw
2 - Bushing
3 - Brake pedal
❑ removing and installing
⇒ page 161
4 - Bearing bracket
❑ for foot controls
❑ removing and installing
⇒ page 161
5 - Self-locking nut, 25 Nm
❑ replace after each re‐
moval
6 - Self-locking nut, 25 Nm
❑ replace after each re‐
moval
7 - Cover
8 - Bearing shell
9 - Retaining clip
❑ for the spherical head of
the pressure rod of the
brake servo unit

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

160
 Roomster 2006 ➤
Brake systems - Edition 02.2014

4.12 Removing and installing the foot con‐

trols from MY 2011 - right-hand drive
Removing
– Remove cover of fuse box -1-.
– Unscrew the fuse box and lay it to the side.
– Remove the footwell vent ⇒ Heating, Air Conditioning; Rep.
gr. 80 .
– Disconnect the plug connection from the accelerator pedal
position sender.

– Unscrew the plastic nuts -arrows-.

– Remove the foot rest -1- and the steering column trim panel
-2-.
– Separating the brake pedal from the brake servo unit
⇒ page 157 .

– Unscrew the nuts -arrows- on the foot controls.

– Remove the foot controls.
Install
Installation is carried out in the reverse order.
– Clip the brake pedal onto the brake servo unit ⇒ page 157 .

4.13 Removing and installing the brake ped‐

als from MY 2011 - right-hand drive
Removing
– Remove the foot controls ⇒ page 161 .

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

161
 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Unscrew nut -2-.

– Release screw -1-.
– Remove brake pedal.
Install
Installation is carried out in the reverse order.

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

162
 Roomster 2006 ➤
Brake systems - Edition 02.2014

47 – Brakes - hydraulics
1 Repairing brake caliper
⇒ “1.1 Summary of components of the brake caliper of the FS-III
brake at the front”, page 163
⇒ “1.2 Removing and installing brake caliper piston of front FS-III
brake”, page 164
⇒ “1.3 Summary of components of the brake caliper of the C54
brake at the front”, page 166
⇒ “1.4 Removing and installing brake caliper piston of front C54
brake”, page 167
⇒ “1.5 Repairing brake caliper FN3”, page 167
⇒ “1.6 Removing and installing brake caliper piston FN3”,
page 167
⇒ “1.7 Summary of components of the brake caliper of the brake
at the rear”, page 170
⇒ “1.8 Removing and installing brake caliper piston of rear brake”,
page 171

1.1 Summary of components of the brake caliper of the FS-III brake at the front

Note

♦ Install the complete repair set when undertaking repairs.

♦ The brake calipers must be pre-bled before installing them in the vehicle (without brake pads) in case of a
repair or when replacing them with new brake calipers ⇒ page 172 .
♦ Thinly coat brake cylinder, piston and gasket ring with lithium grease - G 052 150 A2- .

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

1. Repairing brake caliper 163

 Roomster 2006 ➤
Brake systems - Edition 02.2014

1 - Dust cap
2 - Bleeder valve, 10 Nm
❑ thinly coat thread with
lithium grease - G 052
150 A2- before screwing
in
3 - Bushing
❑ insert into the brake cal‐
iper
4 - Guide bolt, 30 Nm
5 - Cover caps
❑ insert in bushing
6 - Brake caliper
7 - Sealing ring
❑ removing and installing
⇒ page 164
8 - Piston
❑ removing and installing
⇒ page 164
9 - Collar
❑ removing and installing
⇒ page 164 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ do not damage when unless
in‐withauthorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
serting the piston

1.2 Removing and installing brake caliper

piston of front FS-III brake
Special tools and workshop equipment required
♦ Piston jig - MP9-403-
♦ Plastic wedge - 3409-
♦ Lithium grease - G 052 150 A2-
Removing:
– Insert wooden plate to avoid damaging the piston as it is being
pressed out.
– Press the piston out of the brake caliper housing using com‐
pressed air -arrow-.

Note

Make sure that the cylinder surface is not damaged when remov‐
ing the gasket ring.

164 Rep. gr.47 - Brakes - hydraulics

 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Take out gasket ring with plastic wedge - 3409- .

Installing:
– Clean piston and gasket ring with white spirits and dry off.
– Before installing the piston and gasket ring in the brake caliper
housing thinly coat with lithium grease - G 052 150 A2- .
– Insert new gasket ring in the groove of the brake caliper.

– Position the collar with the outer sealing lip on the piston.

Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Insert the inner sealing lip of the collar into the groove of the
cylinder using the plastic wedge - 3409- .
To do so hold the piston with the hand.

– Press the piston into the brake caliper using the piston reset‐
ting jig - MP9-403- .

Note

The outer sealing lip of the collar will engage in the piston groove.

1. Repairing brake caliper 165

 Roomster 2006 ➤
Brake systems - Edition 02.2014

1.3 Summary of components of the brake caliper of the C54 brake at the front

Note

♦ Install the complete repair set when undertaking repairs.

♦ The brake calipers must be pre-bled before installing them in the vehicle (without brake pads) in case of a
repair or when replacing them with new brake calipers ⇒ page 172 .
♦ Thinly coat brake cylinder, piston and gasket ring with lithium grease - G 052 150 A2- .

1 - Dust cap
2 - Bleeder valve, 10 Nm
❑ thinly coat thread with
lithium grease - G 052
150 A2- before screwing
in
3 - Screw, 30 Nm
❑ replace after each re‐
moval
4 - Guide bolt
5 - Collar
❑ insert into the slot of the
brake carrier and of the
guide pin; grease the
slot first using grease
packing from the repair
kit
6 - Brake carrier with guide
bolts and protective caps
❑ is supplied as replace‐
ment part assembled
with guide pin and pro‐
tective caps as well as
adequate quantity of
grease on guide pinsby copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
Protected
❑ if there is any damage to
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
the boots or guide bolts
fit a repair set (use the
enclosed grease pack‐
ing to grease the guide
bolts)
7 - Collar
❑ removing and installing
⇒ page 167
❑ do not damage when inserting the piston
8 - Piston
❑ removing and installing ⇒ page 167
9 - Sealing ring
❑ removing and installing ⇒ page 167
10 - Brake caliper

166 Rep. gr.47 - Brakes - hydraulics

 Roomster 2006 ➤
Brake systems - Edition 02.2014

1.4 Removing and installing brake caliper

piston of front C54 brake
Removing and installing the piston occurs in the same way as for
the brake caliper piston of the FS-III brake ⇒ page 164 .

1.5 Repairing brake caliper FN3

1 - Cover caps
❑ insert in bushing
2 - Guide bolt, 30 Nm
3 - Bushing
❑ insert into the brake cal‐
iper
4 - Dust cap
❑ place on the vent valve
5 - Bleeder valve, 10 Nm
❑ thinly coat thread with
lithium grease -
G 052 150 A2- before
screwing in
6 - Brake caliper
7 - Brake carrier
❑ crewed to the brake cal‐
iper
8 - Retaining spring
❑ insert with both ends in‐
to the bores in the brake
caliper
9 - Sealing ring
❑ removing and installing
⇒ page 167
10 - Piston
❑ removing and installing
⇒ page 167
❑ First thinly coat piston
with lithium grease -
G 052 150 A2-
11 - Protective cap
❑ removing and installing ⇒ page 167
❑ do not damage when inserting the piston

1.6 Removing and installing brake caliper

piston FN3
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
Special tools and workshop equipment required
♦ Disassembly wedge - 3409-
♦ Piston jig - T10145-
♦ Assembly tool - T10146/6-

1. Repairing brake caliper 167

 Roomster 2006 ➤
Brake systems - Edition 02.2014

Removing:
– Press the piston out of the brake caliper using compressed air.
– Insert wooden plate in the channel so that the piston is not
damaged.

– Lever off protective cap with disassembly wedge - 3409- from

the brake caliper.

– Remove gasket ring with disassembly wedge - 3409- .

Note

When removing, make sure that the cylinder surface is not dam‐
aged.

Installing:
– Clean piston and gasket ring with white spirits and dry off.
– Before inserting the piston and gasket ring, thinly coat with
lithium grease - G 052 150 A2- .
– Insert gasket ring into the brake caliper.

– Position the protective cap -A- on the assembly tool -

T10146/6- -1-.

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

168 Rep. gr.47 - Brakes - hydraulics

 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Press the protective cap with the assembly tool -1- and the
piston jig -2- onto the brake caliper in such a way that it is
resting all around the brake caliper.

– Check fitting of the protective cap.

Note

The protective cap should no longer be removable by hand from

the brake caliper.

– Lightly press the piston onto the protective cap and interlock
in this position, e.g. with the disassembly wedge -2-.

Note

Do not tilt the piston, in order to avoid damage to the protective

cap.

– Blow up the protective cap with compressed air (max. 0.3

MPa) -1-. At the same time the protective cap jumps onto the
piston.

– Press the piston with the piston jig -1- into the brake caliper.
The outer sealing lip ofbythe
Protected protective
copyright. cap
Copying for willorengage
private commercial in the piston
purposes, in part or in whole, is not permitted
groove. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

1. Repairing brake caliper 169

 Roomster 2006 ➤
Brake systems - Edition 02.2014

1.7 Summary of components of the brake caliper of the brake at the rear

Note

♦ Install the complete repair set when undertaklng repairs.

♦ The brake calipers must be pre-bled before installing them in the vehicle (without brake pads) in case of a
repair or when replacing them with new brake calipers ⇒ page 172 .
♦ Thinly coat brake cylinder, piston and gasket ring with lithium grease - G 052 150 A2- .

1 - Self-locking screw, 35 Nm
❑ replace after each re‐
moval
❑ counterhold on the
guide bolt when releas‐
ing and tightening
2 - Dust cap
3 - Bleeder valve, 10 Nm
❑ thinly coat thread with
lithium grease - G 052
150 A2- before screwing
in Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
4 - Guide bolt with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

❑ grease before fitting the

collar - Pos. 5
❑ use the grease packing
supplied with the repair
kit
5 - Collar
❑ pull onto brake carrier
and guide bolt
6 - Brake carrier with guide
bolts and protective caps
❑ must be assembled with
sufficient grease on the
guide bolt, supplied as a
spare part
❑ if there is any damage to
the boots or guide bolts
fit a repair set (use the
enclosed grease pack‐
ing to grease the guide
bolts)
7 - Collar
❑ removing and installing ⇒ page 171
❑ do not damage when inserting the piston
8 - Piston with automatic adjusting device
❑ removing and installing ⇒ page 171
9 - Sealing ring
❑ removing and installing ⇒ page 171
10 - Brake caliper housing with lever for the handbrake cable
❑ replace brake caliper housing if the lever for the handbrake cable is not sealed
❑ pre-bleed brake caliper housing after undertaking replacement ⇒ page 172

170 Rep. gr.47 - Brakes - hydraulics

 Roomster 2006 ➤
Brake systems - Edition 02.2014

1.8 Removing and installing brake caliper

piston of rear brake
Special tools and workshop equipment required
♦ Resetting tool - T10165-
♦ Plastic wedge - 3409-
♦ Bleeding bottle (commercially available)
♦ Grease - G 052 150 A2-
♦ Brake fluid ⇒ page 13
Removing:
– Insert the resetting tool - T10165- in such a way that the collar
of the resetting tool is resting on the piston.
– Release the piston by turning the knurled wheel of the reset‐
ting tool - T10165- to the left.
Use open-jawed spanner on a provided spanner surface -A- if the
piston is difficult to move.

Note

Make sure that the cylinder surface is not damaged when remov‐
ing the gasket ring.

– Take out gasket ring with plastic wedge - 3409- .

Installing:
– Clean piston and gasket ring with white spirits and dry off.
– Before inserting the piston and gasket ring in the brake caliper,
thinly coat with grease - G 052 150 A2- .
– Insert new gasket ring in the brake caliper.

– Position the collar with the outer sealing lip on the piston.

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

1. Repairing brake caliper 171

 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Insert the inner sealing lip of the collar into the groove of the
cylinder using the plastic wedge - 3409- .
To do so hold the piston with the hand.

– Insert resetting tool - T10165- .

– Use special tool - T10165/1- for installing.
– Screw in piston by turning the knurled wheel to the right.
Use open-jawed spanner on a provided spanner surface -A- if the
piston is difficult to move.

Note

♦ When resetting the piston with a resetting tool the automatic

piston setting in the brake caliper is destroyed.
♦ It is absolutely necessary, if repairs are being undertaken, to
pre-bleed the brake calipers before installing them in the ve‐
hicle (without brake pads) ⇒ page 172 .

– Insert brake pads.

1.8.1
Protected byTemporary
copyright. Copying for filling of brake
private or commercial caliper
purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Note

Set up brake caliper vertically for pre-bleeding.

– Open vent valve -arrow A-.

– Using a commercially available ventilation reservoir pour in
brake fluid until bubble-free brake fluid drips out of the threa‐
ded bore (brake hose connection) -arrow B-.
– Close vent valve.

172 Rep. gr.47 - Brakes - hydraulics

 Roomster 2006 ➤
Brake systems - Edition 02.2014

2 Brake Servo Unit, Master Brake Cyl‐

inder
⇒ “2.1 Summary of components of brake servo unit, master brake
cylinder up to MY 2010”, page 173
⇒ “2.2 Summary of components of brake servo unit, master brake
cylinder as of MY 2011 - left-hand drive”, page 176
⇒ “2.3 Summary of components of brake servo unit, master brake
cylinder as of MY 2011 - right-hand drive”, page 177
⇒ “2.4 Brake light switch F as of MY 2011”, page 178
⇒ “2.5 Checking the master brake cylinder for tightness”,
page 179
⇒ “2.6 Removing and installing master brake cylinder - left-hand
drive”, page 181
⇒ “2.7 Removing and installing master brake cylinder - right-hand
drive”, page 185
⇒ “2.8 Removing and installing brake servo unit - left-hand drive”,
page 189
⇒ “2.9 Removing and installing brake servo unit - right-hand
drive”, page 191
⇒ “2.10 Checking the non-return valve”, page 192
⇒ “2.11 Removing and installing tandem pump for fuel and vac‐
uum supply”, page 192
⇒ “2.12 Removing and installing the vacuum pump for the vacuum
supply”, page 193

2.1 Summary of components of brake servo unit, master brake cylinder up to

MY 2010

Note
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
The complete master brake cylinder and brake servo unit can be replaced independently of one another.
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

2. Brake Servo Unit, Master Brake Cylinder 173

 Roomster 2006 ➤
Brake systems - Edition 02.2014

1 - Brake servo unit

❑ on LHD vehicles, the
brake servo unit is loca‐
ted on the left in direc‐
tion of travel
❑ on RHD vehicles, the
brake servo unit is loca‐
ted on the right in direc‐
tion of travel
❑ removing and installing -
LHD version
❑ removing and installing -
RHD version
❑ Assignment ⇒ Electron‐
ic Catalogue of Original
Parts
❑ on petrol engines the re‐
quired negative pres‐
sure is drawn from the
intake manifold
❑ Diesel engines are fitted
with a vacuum pump or
tandem pump for fuel
and negative pressure
supply
Inspect proper operation:

– With the engine off

press down brake pedal
repeatedly with force
(this reduces the pres‐
sure already present in
the device).

– Now hold the brake ped‐

al in brake position us‐
ing a medium foot pres‐
sure and start the
engine. If the brake servo unit operates perfectly the brake pedal must yield noticeably under your foot
(servo boost takes effect).
❑ if there are faults replace completely
❑ Checking vacuum system ⇒ page 194
❑ disconnect from brake pedal or clip onto brake pedal ⇒ page 189
❑ Non-return valve (in vacuum hose); Functional test ⇒ page 192
❑ Non-return valve in the vacuum hose of the tandem pump for fuel and vacuum supply ⇒ page 192
2 - Brake fluid level warning contact - F34-
❑ cannot be removed or repaired
3 - Cap Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
4 - Brake fluid reservoir
❑ removing:
– Drain brake fluid.

– Press out retaining pin from the lateral catches of the brake fluid reservoir and master brake cylinder.

– Pull brake fluid reservoir upwards out of the plugs.

❑ Installing:
Installation is carried out in the reverse order.

– Fill up with new brake fluid.

174 Rep. gr.47 - Brakes - hydraulics

 Roomster 2006 ➤
Brake systems - Edition 02.2014

– On vehicles without ABS or with ABS, ABS/TCS BOSCH 8.0 bleed brake system ⇒ page 198

– Perform basic setting using the vehicle diagnosis, measurement and information system - VAS- .
⇒ page 20

5 - Plugs
❑ moisten with brake fluid and press in brake fluid reservoir
6 - Self-locking nut, 20 Nm
❑ replace after each installation
7 - Master brake cylinder
❑ cannot be repaired, replace completely in the event of faults
❑ test tightness ⇒ page 179
❑ removing and installing ⇒ page 181
❑ Assignment ⇒ Electronic Catalogue of Original Parts
8 - Retaining pin
❑ to secure brake fluid reservoir at brake master cylinder
9 - Sealing ring
❑ replace after removal the master brake cylinder
10 - Plugs
11 - Vacuum hose
❑ insert with brake servo unit
12 - Cap
❑ check for firm seating
13 - Self-locking nuts, 25 Nm
❑ replace after each removal
14 - Gasket
❑ for brake servo unit

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

2. Brake Servo Unit, Master Brake Cylinder 175

 Roomster 2006 ➤
Brake systems - Edition 02.2014

2.2 Summary of components of brake servo unit, master brake cylinder as of

MY 2011 - left-hand drive

1 - Cap
2 - Brake fluid level warning
contact - F34-
3 - Brake fluid reservoir
4 - Plugs
5 - Brake servo unit
❑ on petrol engines the re‐
quired negative pres‐
sure is drawn from the
intake manifold
❑ vehicles using a diesel
engine are fitted with a
vacuum pump for gen‐
erating a low pressure
❑ Inspect proper opera‐
tion:
– With the engine off
press down brake pedal
repeatedly with force
(this reduces the low
pressure already
present in the system).

– Now hold the brake ped‐

al in brake position us‐
ing a medium foot pres‐
sure and start the
engine. If the brake ser‐
vo unit operates perfect‐
ly the brake pedal must
yield noticeably under
your foot (servo boost
takes effect).
❑ if defective, replace
completely (check all
the vacuum lines be‐
forehand)
❑ Non-return valve (in vacuum hose); Functional test ⇒ page 192
❑ separate from brake pedal ⇒ page 157
❑ removing and installing ⇒ page 189
6 - Gasket
❑ for brake servo unit
7 - Self-locking nut, 25 Nm
❑ replace after each removal
8 - Compression ring
❑ replace after removal the master brake cylinder
9 - Master brake cylinder
❑ cannot be repaired, replace completely in the event of faults
❑ test tightness ⇒ page Protected
179 by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
❑ removing and installingwith
⇒ page 181
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
❑ Assignment ⇒ Electronic Catalogue of Original Parts

176 Rep. gr.47 - Brakes - hydraulics

 Roomster 2006 ➤
Brake systems - Edition 02.2014

10 - Brake light switch - F-

❑ Including brake pedal switch - F47-
❑ removing and installing ⇒ page 178
11 - Screw, 7 Nm
12 - Self-locking nut, 25 Nm
❑ replace after each removal
13 - Retaining pin
14 - Plugs
❑ moisten with brake fluid and press in brake fluid reservoir

2.3 Summary of components of brake servo unit, master brake cylinder as of

MY 2011 - right-hand drive

1 - Brake servo unit

❑ on petrol engines the re‐
quired negative pres‐
sure is drawn from the
intake manifold
❑ vehicles using a diesel Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
engine are fitted with a unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
vacuum pump for gen‐
erating a low pressure
❑ Inspect proper opera‐
tion:
– With the engine off
press down brake pedal
repeatedly with force
(this reduces the low
pressure already
present in the system).

– Now hold the brake ped‐

al in brake position us‐
ing a medium foot pres‐
sure and start the
engine. If the brake ser‐
vo unit operates perfect‐
ly the brake pedal must
yield noticeably under
your foot (servo boost
takes effect).
❑ if defective, replace
completely (check all
the vacuum lines be‐
forehand)
❑ Non-return valve (in
vacuum hose); Func‐
tional test ⇒ page 192
❑ separate from brake
pedal ⇒ page 157
❑ removing and installing
⇒ page 191
2 - Gasket
❑ for brake servo unit

2. Brake Servo Unit, Master Brake Cylinder 177

 Roomster 2006 ➤
Brake systems - Edition 02.2014

3 - Vacuum hose
❑ Assignment ⇒ Electronic Catalogue of Original Parts
4 - Self-locking nuts, 25 Nm
❑ replace after each removal
5 - Bearing bracket
❑ for foot controls
❑ removing and installing ⇒ page 161
6 - Sealing ring
❑ replace after removal the master brake cylinder
7 - Master brake cylinder
❑ cannot be repaired, replace completely in the event of faults
❑ test tightness ⇒ page 179
❑ removing and installing ⇒ page 185
❑ Assignment ⇒ Electronic Catalogue of Original Parts
8 - Screw 7 Nm
9 - Brake light switch - F-
❑ unless
Including
authorisedbrake pedal
AUTO switch - F47-
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
by ŠKODA A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
❑ removing and installing ⇒ page 178
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

10 - Self-locking nuts, 25 Nm
❑ replace after each removal
11 - Brake line
❑ from main braking cylinder to ABS control unit (floating piston circuit)
❑ identification marking of the ABS unit “HZ2”
❑ M 12 x 1
12 - Brake line
❑ from main braking cylinder to ABS control unit (push rod piston circuit to control unit)
❑ identification marking of the ABS unit “HZ1”
❑ M 12 x 1
13 - Plugs
❑ moisten with brake fluid and press in brake fluid reservoir
14 - Brake fluid reservoir
15 - Screw cap
16 - 4 Nm

2.4 Brake light switch - F- as of MY 2011

Removing:
– Remove air filter.

178 Rep. gr.47 - Brakes - hydraulics

 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Disconnect the plug connection -1- at the brake light switch -

F- .
– Screw out screw -2- from master brake cylinder. Tightening
torque ⇒ Item 11 (page 177) .
– Remove the brake light switch - F- -3- from the master brake
cylinder and then take it out of the catch of the master brake
cylinder.
Installing:
– Installation is carried out in the reverse order.

2.5 Checking the master brake cylinder for

tightness
Special tools and workshop equipment required
♦ Brake-power regulator or brake system tester , e.g. -V.A.G
1310- or -V.A.G 1310 A-
♦ Lithium grease - G 052 150 A2-
Test condition
• Function and tightness of the brake system (hydraulic control
unit or load-dependent brake-power regulator, brake lines,
brake hoses, brake caliper and wheel-brake cylinder) O.K.
Inspection:
– Release the vent valve on one of the front brake calipers.
– Connect the pressure gauge of the tester - V.A.G 1310 - or -
V.A.G 1310 A- and bleed -V.A.G 1310 A- .
– Push down brake pedal until the pressure gauge on the tester
indicates 5 MPa (50 bar).
– Throughout the test which lasts 45 seconds the pressure loss
must not exceed 0.4 MPa (4 bar).
– If the pressure loss exceeds 0,4 MPa (4 bar) replace the mas‐
ter brake cylinder.

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

2. Brake Servo Unit, Master Brake Cylinder 179

 Roomster 2006 ➤
Brake systems - Edition 02.2014

Tightening torque:
Vent valve in brake caliper 10 Nm

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

180
 Roomster 2006 ➤
Brake systems - Edition 02.2014

2.6 Removing and installing master brake

cylinder - left-hand drive
Special tools and workshop equipment required
♦ Hose clamp - MP7-602 (3094)-
♦ Removal and installation pliers , e.g. -VAS 6340-
♦ Vehicle diagnosis, measurement and information system -
VAS-
♦ Brake filling and bleeding device , e. g. -VAS 5234-
♦ Extraction bottle (commercially available)
♦ Repair kit -1H0 698 311 A-
♦ Brake fluid ⇒ page 13

Note

♦ The master brake cylinder must not be repaired.

♦ Assignment ⇒ Electronic Catalogue of Original Parts .

Removing:
– Remove engine cover ⇒ engine; Rep. gr. 10 .
– Remove air filter ⇒ Engine; Rep. gr. 24 (fuel engines) or ⇒
Engine; Rep. gr. 23 (diesel engines).
– Remove battery and battery tray ⇒ Electrical System; Rep.
gr. 27 .
– Lay sufficient non-fluffing cloths around the engine and gear‐
box.

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

181
 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Disconnect plug -1- from the brake fluid level warning contact
- F34- .
For vehicles as of MY 2011
– Disconnect plug from brake light switch - F- ⇒ page 178 .
Continued for all vehicles
– Unclip vacuum hose -6- from the brake fluid reservoir.
– After opening the bleeder valves on the front wheel brake cal‐
lipers, pump the brake fluid out of the brake fluid reservoir by
repeatedly pressing the brake pedal.
– Clamp off the running-on line of the clutch master cylinder
-2- with hose clamp - MP7-602 (6340)- .
– Open spring strap clamps of the running-on line of the clutch
master cylinder -2- using assembly pliers .
– Disconnect the running-on line of the clutch master cylinder
-2- from the brake fluid reservoir -3- and tie up.
– Unclip the brake lines from the holder -7-.
– Unscrew the brake lines from the master brake cylinder -5- and
shut off.
– Shut-off the connections of the brake lines on the master brake
cylinder with screw plugs from the repair kit -1H0 698 311 A- .
– Release the nuts of the master brake cylinder -arrows-.
– Carefully pull off the master brake cylinder -5- from the brake
servo unit -4-.
Installing:

Note

♦ Install new gasket ring between the master brake cylinder and
the brake servo unit.
♦ When installing the master brake cylinder with the brake servo
unit pay attention to the correct positioning of the pressure rod
in the master brake cylinder.
♦ Only fill up with new brake fluid.

Installation is by
Protected carried
copyright.out in the
Copying reverse
for private order.purposes, in part or in whole, is not permitted
or commercial
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Fill upwith
with new
respect brake
to the fluid.
correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

– Install the battery tray and battery ⇒ Electrical System; Rep.

gr. 27 .
– Connect battery ⇒ Electrical System; Rep. gr. 27 .
Vehicles without ABS and with ABS, ABS/TCS BOSCH 8.0
– Bleeding brake system ⇒ page 198 .
Vehicles with ABS//TCS/ESP BOSCH 8.0
– Perform basic setting of vehicle diagnosis, measurement and
information system - VAS- ⇒ page 22 .
Continued for all vehicles
– Bleed clutch ⇒ Gearbox; Rep. gr. 30 .
– Install air filter ⇒ Engine; Rep. gr. 24 (petrol engines) or ⇒
Engine; Rep. gr. 23 (diesel engines).
– Install engine cover ⇒ engine; Rep. gr. 10 .

182
 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Perform a vehicle system test using the vehicle diagnosis,

measurement and information system - VAS- ⇒ page 23 .

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

183
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Tightening torques:
Master brake cylinder to brake servo unit 25 Nm
♦ Use new nuts!

Brake lines to master brake cylinder 14 Nm

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

184
 Roomster 2006 ➤
Brake systems - Edition 02.2014

2.7 Removing and installing master brake

cylinder - right-hand drive
Special tools and workshop equipment required
♦ Closing tool - T10249-
♦ Removal and installation pliers , e.g. -VAS 6340-
♦ Vehicle diagnosis, measurement and information system -
VAS-
♦ Brake filling and bleeding device , e. g. -VAS 5234-
♦ Extraction bottle (commercially available)
♦ Repair kit -1H0 698 311 A-
♦ Brake fluid ⇒ page 13

Note

♦ The master brake cylinder must not be repaired.

♦ Assignment ⇒ Electronic Catalogue of Original Parts .

Removing:
– Remove engine cover ⇒ engine; Rep. gr. 10 .
Vehicles TDI without diesel particle filter
– Release clamps -arrows- with assembly pliers and remove top
charge air pipe -1- with connecting hose -2-.
Continued for all vehicles
– After opening the bleeder valves on the front wheel brake cal‐
lipers, pump the brake fluid out of the brake fluid reservoir by
repeatedly pressing the brake pedal.
– Lay sufficient non-fluffing cloths around the engine.

– Detach the hose-2- of the running-on line to the clutch master

cylinder from the brake fluid reservoir -4-.
– Seal hose -2- with closing tool - T10249- -1-.
– Tie up hose -2-.

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

185
 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Disconnect plug -1- from the brake fluid level warning contact
- F34- .

– Unscrew plug -arrow-.

– Pull the brake fluid reservoir carefully out of the plugs of the
master brake cylinder.

– Mark brake lines -1-.

– Unscrew the brake lines -1- from the master brake cylinder
-2- and shut off.
– Detach vacuum lines -3- and place to the side.
– Shut-off the connections of the brake lines on the master brake
cylinder with screw plugs from the repair kit -1H0 698 311 A- .

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

186
 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Release the nuts of the master brake cylinder -arrows-.

– Carefully pull off the master brake cylinder -1- from the brake
servo unit.
For vehicles as of MY 2011
– Disconnect plug from brake light switch - F- ⇒ page 178 .
Installing:

Note

♦ Install new gasket ring between the master brake cylinder and
the brake servo unit.
♦ When installing the master brake cylinder with the brake servo
unit pay attention to the correct positioning of the pressure rod
in the master brake cylinder.
♦ Only fill up with new brake fluid.

Installation is carried out in the reverse order.

– Fill up with new brake fluid.
Vehicles without ABS and with ABS, ABS/TCS BOSCH 8.0
– Bleeding brake system ⇒ page 198 .
Vehicles with ABS//TCS/ESP BOSCH 8.0
– Perform basic setting of vehicle diagnosis, measurement and
information system - VAS- ⇒ page 22 .
Continued for all vehicles
– Bleed clutch ⇒ Gearbox; Rep. gr. 30 .
– Install engine cover ⇒ engine; Rep. gr. 10 .
– Perform a vehicle system test using the vehicle diagnosis,
measurement and information system - VAS- ⇒ page 23 .

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

187
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Tightening torques:
Master brake cylinder to brake servo unit 25 Nm
♦ Use new nuts!

Brake lines to master brake cylinder 14 Nm

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

188
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2.8 Removing and installing brake servo

unit - left-hand drive
Special tools and workshop equipment required
♦ Hose clamp - MP7-602 (3094)-
♦ Release tool - T10159A-
♦ Vehicle diagnosis, measurement and information system -
VAS-
♦ Brake filling and bleeding device , e. g. -VAS 5234-
♦ Extraction bottle (commercially available)
♦ Repair kit part number 1H0 698 311 A
♦ Brake fluid ⇒ page 13
Removing:
– Remove master brake cylinder ⇒ page 181 .
Vehicles without air conditioning system
– Removing the left footwell vent ⇒ Heating, Air Conditioning;
Rep. gr. 80 .
For vehicles with air conditioning
– Removing the left footwell vent ⇒ Heating, Air Conditioning;
Rep. gr. 87 .
Vehicles with Convenience system central control unit - J393-
– Removing the convenience system central control unit - J393-
⇒ Body Work; Rep. gr. 70 .
For vehicles up to MY 2010
– Remove brake light switch ⇒ page 146 .
Continued for all vehicles
– Separate brake pedal from brake servo ⇒ page 159 .
– Unscrew the nuts for brake servo unit -arrows-.
– Guide the brake servo unit with master brake cylinder towards
the front.
Installing:
Installation is carried out in the reverse order.
– Clip the brake pedal onto the brake servo unit ⇒ page 159 .
For vehicles up to MY 2010
– Install and set the brake light switch ⇒ page 146 .
Continued for all vehicles
– Fill up with new brake fluid.
– Install the battery tray and battery ⇒ Electrical System; Rep.
gr. 27 .
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
– Connect battery ⇒ Electrical System; Rep. gr.by ŠKODA
unless authorised 27 . AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Bleed clutch ⇒ Gearbox; Rep. gr. 30 .
– Install air filter ⇒ Engine; Rep. gr. 24 (petrol engines) or ⇒
Engine; Rep. gr. 23 (diesel engines).
– Install engine cover ⇒ engine; Rep. gr. 10 .

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Tightening torques:
Brake servo unit to foot controls 25 Nm
♦ Use new nuts!

Brake lines to master brake cylinder 14 Nm

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

190
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2.9 Removing and installing brake servo

unit - right-hand drive
Special tools and workshop equipment required
♦ Closing tool - T10249-
♦ Release tool - T10159A-
♦ Vehicle diagnosis, measurement and information system -
VAS-
♦ Brake filling and bleeding device , e. g. -VAS 5234-
♦ Extraction bottle (commercially available)
♦ Repair kit part number 1H0 698 311 A
♦ Brake fluid ⇒ page 13
Removing:
– Remove engine cover ⇒ engine; Rep. gr. 10 .
Vehicles TDI without diesel particle filter
– Release clamps -arrows- with assembly pliers and remove top
charge air pipe -1- with connecting hose -2-.
Vehicles with diesel particle filter
– Remove diesel particle filter ⇒ Engine; Rep. gr. 26
For vehicles up to MY 2010
– Remove brake light switch ⇒ page 146
Continued for all vehicles
– Remove master brake cylinder ⇒ page 185
– Remove the cooling water tank cover ⇒ Body Work; Rep. gr.
66 .
– Remove air filter ⇒ Engine; Rep. gr. 24 (fuel engines) or ⇒
Engine; Rep. gr. 23 (diesel engines).
– Pull the engine control unit out of the bracket and lay to the
side.
– Remove engine control unit bracket.
– Remove bulkhead ⇒ Body work; Rep. gr. 66 .
– Disconnect the electrical cable with clips from the brake servo
unit.
– Pull the rubber grommet with the electrical cable out of the
water channel and place the cable to the side.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Unclip the brake
with respect lines from
to the correctness the holder
of information -arrow-.Copyright by ŠKODA AUTO A. S.�
in this document.

– Remove the damper below the dash panel on the driver side
⇒ Body Work; Rep. gr. 70 .
– Separating the brake pedal from the brake servo unit
⇒ page 161 .

191
 Roomster 2006 ➤
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– Unscrew the nuts for brake servo unit -arrows-.

– Push engine forwards with aid of 2nd mechanic.
– Guide the brake servo unit with master brake cylinder towards
the front.
Install
Installation is carried out in the reverse order.
– Clip the brake pedal onto the brake servo unit ⇒ page 161 .
For vehicles up to MY 2010
– Install and set the brake light switch ⇒ page 146 .
Continued for all vehicles
– Fill up with new brake fluid.
– Bleeding brake system ⇒ page 198 .
– Bleed clutch ⇒ Gearbox; Rep. gr. 30 .
– Install air filter ⇒ Engine; Rep. gr. 24 (petrol engines) or ⇒
Engine; Rep. gr. 23 (diesel engines).
– Install engine cover ⇒ engine; Rep. gr. 10 .
Tightening torques:
Brake servo unit to foot controls 25 Nm
♦ Use new nuts!

Master brake cylinder to brake servo unit 25 Nm

♦ Use new nuts!

Brake lines to master brake cylinder 14 Nm

Brake fluid reservoir
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S.4does
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
on the master brake cylinder Nmnot guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

2.10 Checking the non-return valve

– Air must pass through non-return valve -A- in direction of ar‐
row.
– The non-return valve must be closed to the passage of air in
the reverse direction.
Pay attention to correct installation position.

2.11 Removing and installing tandem pump

for fuel and vacuum supply
For vehicles with TDI PD Turbocharger engines
The vacuum supply of the brake servo unit occurs via a tandem
pump on vehicles with turbocharger engines ⇒ Engine; Rep. gr.
20 (diesel engines).

192
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2.12 Removing and installing the vacuum

pump for the vacuum supply
For vehicles with TDI CR turbocharger engines
The vacuum supply of the brake servo unit occurs via a vacuum
pump on vehicles with turbocharger engines ⇒ Engine; Rep. gr.
15 (diesel engines).

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

193
 Roomster 2006 ➤
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3 Checking vacuum system

⇒ “3.1 Connecting vacuum gauge for brake servo VAS 6721 ”,
page 194
⇒ “3.2 Checking vacuum generation”, page 195
⇒ “3.3 Checking for leaks”, page 195
⇒ “3.4 Vacuum generation with manual vacuum pump VAS 6213
”, page 197

3.1 Connecting vacuum gauge for brake

servo - VAS 6721-
– Pull vacuum hose out of brake servo.
First press the brake pedal several times in order to facilitate re‐
moval of the vacuum hose.
– Place brake servo vacuum gauge - VAS 6721- between them
-see following illustrations-.
Item Com‐ Meaning
num‐ po‐
ber nent
A Cut- In direction of vacuum hose, non-return valve and,
off if included, vacuum pump
valve
B Cut- ♦ Open to facilitate removal of brake servo vac‐
off uum gauge - VAS 6721-
valve
♦ Open to simulate a fault source
♦ Connection of manual vacuum pump - VAS
6213-

C Cut- In direction of brake servo

off
valve

– Push hose -A- of brake servo vacuum gauge - VAS 6721- onto
vacuum hose andProtected
press byadapter -C- into
copyright. Copying brakeor servo.
for private commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

194
 Roomster 2006 ➤
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3.2 Checking vacuum generation

Note

♦ The average air pressure of the earth's atmosphere at sea

level is 1013 mbar and decreases steeply as the altitude in‐
creases (approx. 100 mbar/1,000 m altitude). Local and time
variations also influence the vacuum generation.
♦ A cold engine, a switched-on air-conditioning system as well
as engine idling have an adverse influence on generation of a
vacuum.

– Before starting work, check all vacuum hoses for damage (e.g.
cracks or marten bite) and to check that they are correctly and
firmly attached
– Connect brake servo vacuum gauge - VAS 6721-
⇒ page 194 .
– Open cut-off valve -A-.
– Close cut-off valves -B+C-.
– Start warm engine (>60° C), press accelerator briefly (engine
speed greater than 2000/min).
– Read indicated measured value.
Normally (see notes), the vacuum that is generated should be
between 700 and 950 mbar (depending on engine size).
If the measured value is not reached even through the precondi‐
tions (see notes) have been met, the vacuum system must first
be checked for tightness.
– For comparison purposes, generate the vacuum with the man‐
ual vacuum pump - VAS 6213- ⇒ page 197 .
Open cut-off valve -B- to facilitate removal of hose connections
and adapter.

3.3 Checking for leaks

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

♦ The average air pressure of the earth's atmosphere at sea

level is 1013 mbar and decreases steeply as the altitude in‐
creases (approx. 100 mbar/1,000 m altitude). Local and time
variations also influence the vacuum generation.
♦ A cold engine, a switched-on air-conditioning system as well
as engine idling have an adverse influence on generation of a
vacuum.

– Before starting work, check all vacuum hoses for damage (e.g.
cracks or marten bite) and to check that they are correctly and
firmly attached
– Connect brake servo vacuum gauge - VAS 6721-
⇒ page 194 .

3. Checking vacuum system 195

 Roomster 2006 ➤
Brake systems - Edition 02.2014

– Open cut-off valve -A-.

– Close cut-off valves -B+C-.
– Start warm engine (>60° C), press accelerator briefly (engine
speed greater than 2000/min).
Normally (see notes), the vacuum that is generated should be
between 700 and 950 mbar (depending on engine size).

– Open cut-off valve -C- to evacuate brake servo.

– Switch off engine.
– Read and make a note of measured value shown.
A vacuum decrease of 400 mbar in 12 hours is permissible.
If the vacuum decrease is greater, then check for leaks in the
vicinity of ...
1- Brake servo unit
or
2- Non-return valve, vacuum hoses with connectors and vac‐
uum pump/intake manifold.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
If there are large leaks, the vacuum decreases steeply within a
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

few seconds.
Vacuum check in vicinity of brake servo:

– After generation of vacuum, close cut-off valve -A- in order to

check brake servo vacuum system.
Vacuum check in vicinity of non-return valve, vacuum hoses with
connectors and vacuum pump/intake manifold:

– Once vacuum has been generated, close the shut-off valve

-C- in order to check the vacuum system of the brake servo
vacuum gauge - VAS 6721- up to the intake manifold or the
vacuum pump.
Open cut-off valve -B- to facilitate removal of hose connections
and adapter.

196
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3.4 Vacuum generation with manual vac‐

uum pump - VAS 6213-
Instead of vacuum generation by means of engine or vacuum
pump, the vacuum can be generated with the manual vacuum
pump - VAS 6213- in certain cases.
– Connect manual vacuum pump - VAS 6213- to vacuum hose
from connection -B- on brake servo vacuum gauge - VAS
6721- .
– Open cut-off valve -B-.
– Generate vacuum with hand vacuum pump - VAS 6213- until
between 600 and 950 mbar is shown on brake servo vacuum
gauge - VAS 6721- .
– Subsequently, carry out the corresponding checks.

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

3. Checking vacuum system 197

 Roomster 2006 ➤
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4 Bleeding brake system

⇒ “4.1 Bleeding the hydraulic unit (vehicles with ESP)”,
page 198
⇒ “4.2 Bleeding the brake system using the brake filling and
bleeding device , e.g. VAS 5234 VAS 5234 ”, page 199
⇒ “4.3 Bleeding the brake system of air without using the brake
filling and bleeding device ”, page 200
⇒ “4.4 Change brake fluid”, page 201

WARNING

♦ Brake fluid is hygroscopic, i.e. it retains humidity from the

ambient air, and must therefore always be stored in airtight
containers.
♦ Brake fluid must never come into contact with fluids con‐
taining mineral oils (oil, petrol, cleaning agent). Mineral
oils damage the plugs and boots of the brake system.
♦ Drained (used) brake fluid must never be used again.
♦ Observe the disposal instructions!
♦ Brake fluid is toxic, avoid skin contact.
♦ Because of its causticunless
effect brakebyfluid
authorised ŠKODA must
AUTOnotA. S.come
ŠKODAinto
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
AUTO A. S. does not guarantee or accept any liability
contact with paint. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

♦ Rinse any brake fluid spills with a lot of water.

♦ Dispose of brake fluid in compliance with the applicable
environmental regulations.
♦ Bleeding brake system on vehicles with ABS, ABS/TCS
BOSCH 8.0 or ABS BOSCH 8.2, as for vehicles without
ABS.
♦ On vehicles with load-dependent brake-power regulator,
move the lever of the brake-power regulator while bleed‐
ing the rear wheel-brakes.
♦ Only use new brake fluid ⇒ page 13 .

4.1 Bleeding the hydraulic unit (vehicles

with ESP)
Special tools and workshop equipment required
♦ Vehicle diagnosis, measurement and information system -
VAS-
♦ Brake filling and bleeding device , e. g. -VAS 5234-
♦ Brake fluid ⇒ page 13
– Carry out bleeding ⇒ page 199 .
– Perform basic setting ⇒ Vehicle diagnostic tester.

198
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Caution

Before the basic setting is performed, first of all the brake sys‐
tem must be fully bled until even the smallest air bubbles have
escaped from the system.
The air bubbles would penetrate into the ABS hydraulic unit
when performing the basic setting.
It is very difficult to remove these air bubbles from the ABS
hydraulic unit.

4.2 Bleeding the brake system using the

brake filling and bleeding device , e.g. -
VAS 5234- -VAS 5234-
Special tools and workshop equipment required
♦ Brake filling and bleeding device , e. g. -VAS 5234-
♦ Bleeding bottle (commercially available)
♦ Brake fluid ⇒ page 13

Note

♦ Bleeding of the brake system on vehicles with ABS is under‐

taken in the same way as for vehicles without ABS.
♦ On vehicles without ABS and with load-dependent brake-pow‐
er regulator, move the lever of the brake-power regulator while
bleeding the rear wheel-brake. Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Remove dust caps from the vent valves of the brake calipers/
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

wheel-brake cylinder.
– Switch on the brake filling and bleeding device (at a pressure
of approx. 2 bar) and open the bleeder valves in the prescribed
sequence.
– Bleed the brake calipers or the brake cylinder with the hose of
the bleeding bottle .
– It must be bled until the brake system is fully bled, i.e until even
the smallest air bubbles have escaped.
Bleeding sequence
1. Rear right wheel-brake cylinder/brake caliper
2. Rear left wheel-brake cylinder/brake caliper
3. Front right brake caliper
4. Front left brake caliper
– After bleeding close the relevant vent valve and fit dust cap.
– Disconnect the brake filling and bleeding device .
– Disconnect the brake filling and bleeding device from the
brake fluid reservoir.
– If necessary, correct the brake fluid level in the brake fluid res‐
ervoir.

4. Bleeding brake system 199

 Roomster 2006 ➤
Brake systems - Edition 02.2014

Vehicles with ABS BOSCH 8.0, BOSCH 8.2 and vehicles without
ABS
– Perform a test drive. While doing so, at least one ABS adjust‐
ment must be carried out on vehicles with ABS!

Caution

Before the basic setting is performed, first of all the brake sys‐
tem must be fully bled until even the smallest air bubbles have
escaped from the system.
The air bubbles would penetrate into the ABS hydraulic unit
when performing the basic setting.
It is very difficult to remove these air bubbles from the ABS
hydraulic unit.

Vehicles with ABS//TCS/ESP BOSCH 8.0

– Perform basic setting of vehicle diagnosis, measurement and
information system - VAS- ⇒ page 22 .
– Perform test drive with at least one ABS adjustment!
Vehicles with ABS//TCS/ESP BOSCH 8.2i
– Perform basic setting of vehicle diagnosis, measurement and
information system - VAS- ⇒ Vehicle diagnostic tester.
– Perform test drive with at least one ABS adjustment!

4.3 Bleeding the brake system of air without

using the brake filling and bleeding de‐
vice
Special tools and workshop equipment required
♦ Bleeding bottle (commercially available)
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
♦ Brake fluid ⇒ page 13

Note

♦ Bleeding of the brake system on vehicles with ABS is under‐

taken in the same way as for vehicles without ABS.
♦ On vehicles with load-dependent brake-power regulator,
move the lever of the brake-power regulator while bleeding the
rear wheel-brake.
♦ While bleeding continuously check the brake fluid level in the
brake fluid reservoir and top up brake fluid if necessary up to
the “MAX” marking.

– Build up pressure in the brake system by pumping repeatedly

the brake pedal.
– Fit on hose of bleeding bottle .
– Loosen the vent valve by pressing on the brake pedal and
bleed while doing so.
– Tighten the vent valve with the brake pedal pressed down.
– If required, repeat this procedure until the brake system is bled
fully.

200
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Note

Repeat this procedure until the brake system is fully bled, i.e. until
even the smallest air bubbles have escaped from the system.

Bleeding sequence
1. Rear right wheel-brake cylinder/brake caliper
2. Rear left wheel-brake cylinder/brake caliper
3. Front right brake caliper
4. Front left brake caliper
– After bleeding close the relevant vent valve and fit dust cap.
Vehicles with ABS BOSCH 8.0, ABS BOSCH 8.2 and vehicles
without ABS
– Perform a test drive. While doing so, at least one ABS adjust‐
ment must be carried out on vehicles with ABS!

Caution

Before the basic setting is performed,Protected

first ofbyall the brake
copyright. Copyingsys‐
for private or commercial purposes, in part or in whole, is not permitted
tem must be fully bled until even the unless
smallest air by
authorised bubbles
ŠKODA AUTOhave A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
escaped from the system. with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

The air bubbles would penetrate into the ABS hydraulic unit
when performing the basic setting.
It is very difficult to remove these air bubbles from the ABS
hydraulic unit.

Vehicles with ABS//TCS/ESP BOSCH 8.0

– Perform basic setting of vehicle diagnosis, measurement and
information system - VAS- ⇒ page 22 .
– Perform test drive with at least one ABS adjustment!
Vehicles with ABS//TCS/ESP BOSCH 8.2i
– Perform basic setting of vehicle diagnosis, measurement and
information system - VAS- ⇒ Vehicle diagnostic tester.
– Perform test drive with at least one ABS adjustment!

4.4 Change brake fluid

⇒ Maintenance ; Booklet Roomster

4. Bleeding brake system 201

 Roomster 2006 ➤
Brake systems - Edition 02.2014

5 Brake-power regulator
⇒ “5.1 Summary of components of brake-power regulator”, page
202
⇒ “5.2 Inspecting, setting brake-power regulator and adjusting
values”, page 203
⇒ “5.3 Removing and installing brake-power regulator”,
page 206

5.1 Summary of components of brake-power regulator

Note

♦ After removing the brake lines close connection bores on the brake-power regulator with screw plugs.
♦ Only remove the screw plugs of the connection bores immediately before installing the brake lines.

WARNING

Pay attention to the correct channel assignment of the brake

lines. Interchanging the brake lines will result in dangerous
brake control actions.

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

202
 Roomster 2006 ➤
Brake systems - Edition 02.2014

1 - Brake-power regulator
❑ load dependent
❑ Assignment ⇒ Electron‐
ic Catalogue of Original
Parts
❑ inspecting, setting and
adjusting values
⇒ page 203
2 - Brake line with pipe screw
❑ Tightening torque of
pipe screw: 14 Nm
3 - Screw, 21 Nm
4 - Self-locking nut, 21 Nm
❑ replace after each re‐
moval
5 - Tension spring
6 - Screw, 16 Nm
7 - Socket nut
8 - Screw
❑ replace after each re‐
moval

5.2 Inspecting, setting brake-power regula‐

tor and adjusting values
Special tools and workshop equipment required
♦ Brake-power regulator or brake system tester , e.g. -V.A.G
1310- or -V.A.G 1310 A-
♦ Brake filling and bleeding device , e. g. -VAS 5234-
Fitting location of the brake-power regulator
The brake-power regulator is secured to a bracket assigned to
the mount for rear axle and is controlled by the rear axle move‐
ment via a spring.
Check for proper operation
– Forcefully apply the brake pedal and release quickly (vehicle
is standing on its wheels). While doing so the lever of the
brake-power regulator must move.
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

5. Brake-power regulator 203

 Roomster 2006 ➤
Brake systems - Edition 02.2014

Pressure test and adjustment

Note

♦ The brake-power regulator is adjusted on a vehicle ready for

driving.
♦ Vehicle ready for driving for testing and setting the brake-pow‐
er regulator: Weight of the vehicle with full fuel tank and full
water reservoir for windscreen wiper/washer and headlamp
cleaning system, spare wheel, tool kit, jack (if the vehicle was
fitted at the factory with them) and driver (75 kg). The spare
wheel, tool kit and jack must be located in the position pre‐
scribed by the vehicle manufacturer, the driver must be seated
on the driver seat.

– Raise vehicle and connect pressure gauge of the tester to the

brake caliper (front left wheel) and connect to the wheel-brake
cylinder (rear right wheel).
– Bleed both pressure gauges.
– Lower vehicle and repeatedly depress vehicle and allow to
settle on the rear axle.
– Press brake pedal and measure pressures.
– Compare measured pressure values to the specified adjusting
values ⇒ page 204
– If necessary adjust brake-power regulator ⇒ page 204
Adjusting brake-power regulator
Test pressure on rear axle too high:
– Release tension spring on brake-power regulator.
Test pressure on rear axle too low:Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted
unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
– Tighten tension spring on brake-power regulator.
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�

Note

Adjust without load on the brake pedal. Observe the following se‐
quence:

– Read off values.

– Relieve brake pedal.
– Adjust tension spring on brake-power regulator.
– Again load brake pedal.
– Read-off values and if necessary correct adjustment.
– Remove pressure gauge.
– Bleeding Brake System ⇒ page 198
Adjusting values for the load-dependent brake-power regulator

204
 Roomster 2006 ➤
Brake systems - Edition 02.2014

Note

♦ Adjusting values for the load-dependent brake-power regulator are valid for a vehicle with driver (75kg) ready for driving.
♦ Vehicle ready for driving for setting the brake-power regulator: Weight of the vehicle with full fuel tank and full water reservoir for windscreen wiper/washer and
headlamp cleaning system, spare wheel, jack (if the vehicle was fitted at the factory with them), tool kit, and driver (75 kg). The spare wheel, tool kit and jack must
be located in the position prescribed by the vehicle manufacturer, the driver must be seated on the driver seat.

Model/Version bar MPa bar MPa

Vehicles with electro-hydraulic steering - drum brakes on rear axle Front axle 70 7.0 Front axle 100 10.0
Rear axle 44.4 ± 3 4.44 ± 0.3 Rear axle 57.3 ± 3 5.73 ± 0.3

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

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Brake systems - Edition 02.2014

5.3 Removing and installing brake-power

regulator
Special tools and workshop equipment required
♦ Brake-power regulator or brake system tester , e.g. -V.A.G
1310- or -V.A.G 1310 A-
♦ Brake pedal arrester , e.g. -V.A.G 1238 B- or brake pedal load
-V.A.G 1869/2-
♦ Brake filling and bleeding device , e. g. -VAS 5234-
♦ Catch pan (commercially available)
♦ Repair kit part number 1H0 698 311 A
♦ Brake fluid ⇒ page 13
Removing:
– Actuate brake pedal and arrest with brake pedal arrester .
– Position the catch pan under the brake-power regulator to col‐
lect escaping brake fluid.
– Mark brake lines (for re-installation).
– Unscrew brake lines from brake-power regulator.
– Shut-off brake lines to prevent brake fluid from running out and
soiling.
– Shut-off the connections for the brake lines on the brake-pow‐
er regulator with screw plugs frombythe
Protected repair
copyright. kit part
Copying number
for private or commercial purposes, in part or in whole, is not permitted
1H0 698 311 A. unless authorised by ŠKODA AUTO A. S. ŠKODA AUTO A. S. does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by ŠKODA AUTO A. S.�
– Unscrew the nut ⇒ Item 4 (page 203) and pull out the screw
⇒ Item 8 (page 203) .
– Screw out the oval-head countersunk screws
⇒ Item 3 (page 203) .
– Remove brake-power regulator.
Installing:

WARNING

Pay attention to the correct channel assignment of the brake

lines. Interchanging the brake lines will result in dangerous
brake control actions.

Installation is carried out in the reverse order.

– Bleeding brake system ⇒ page 198 .
– Adjusting brake-power regulator ⇒ page 203 .

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Tightening torques:
Brake-power regulator to bracket 21 Nm
Brake-power regulator to tension spring 21 Nm
Brake line to brake-power regulator 14 Nm

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

207
 Roomster 2006 ➤
Brake systems - Edition 02.2014

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

208