The 2008-2012 Volkswagen Routan is a variant of the Chrysler mini van platform with revised styling, suspension tuning and brake service procedures. So this van has a bit of a split personality when it comes to servicing the brakes.

The owners of the Routan and the Chrysler minivan are two different customers judging by the TSBs. The Routan has five different TSBs about addressing customers who complain about brake noise. The Chrysler mini-van has none. The two vans have almost identical brake systems and assembled in the same plant, so don’t treat the Routan driver like you would a Chrysler minivan driver.

Volkswagen requires SAE J1703 or DOT 4 brake fluid for the Routan. This variation of brake fluid is ideal because of the kinematic viscosity requirements of ABS and ESC systems.

The 3.6 liter equipped Routan uses a vacuum pump to augment normal engine vacuum. Control of the vacuum pump is executed by the PCM. A two-wire electrical connector is utilized to receive power and ground for the vacuum pump. Operating voltage is between 9V – 16V.

Some vehicles with the auxiliary vacuum pump possess the store code DTC P1479 (17887), for a brake vacuum system malfunction. Sometimes this code can be set erroneously due to unexpected changes in engine vacuum or even condensation build-up. To check the vacuum pump, it is imperative to use a scan tool that can perform the bi-directional test for the pump.

As stated before, the Routan driver is more sensitive to brake noise. Always use a premium pad set with new hardware when the pads are replaced.

The stock front disc brakes are equipped with an audible wear indicator on the left side inboard brake pad exclusively. The right side pads do not include an audible wear indicator. Rear disc brakes are equipped with audible wear indicators on both left side and right side inboard brake pads.

The rear calipers have an integrated parking brake in the caliper. Turning the caliper piston will retract the caliper.

The parking brake lever is an automatic-adjusting type that constantly applies a minimal amount of tension to the parking brake cables to keep them in adjustment at all times.

1. Wipe down the front parking brake cable strand until clean at the intermediate bracket area. Do not use any type of sharp instrument directly on the cable strand to hold it in place. Damage to the cable strand or coating may occur.

2. Clamp an suitable pair of pliers on the front parking brake cable button only and pull the cable strand rearward until it stops. Then, grasp the front cable strand and hold it in this position. Remove the pliers from the button.

3. While holding the front cable in this position, install the equalizer (attached to both rear cables) on the front parking brake cable.

4. Release the grasp on the front parking brake cable.

5. Apply and release the parking brake lever one time. This will seat the parking brake cables and allow the auto adjuster in the parking brake lever mechanism to correctly tension the parking brake cables.

Guide Pin: 26ft/lbs.

Caliper Bracket Bolt: 125ft/lbs.

Guide Pin: 26ft/lbs.

Caliper Bracket Bolt: 100 ft/lbs

.002”

Left rear

Right front

Right rear

Left front

For more brake service tutorials and information, please visit our friends at Brake and Front End

Original article authored by Andrew Markel