Front Brakes, PR-1LL and 1LM
Front Brakes, PR-1LL and 1LM
=> [ Brake Pads ]
=> [ Brake Pad Wear Display Wire ]
=> [ Brake Caliper with Brake Carrier ]
=> [ Brake Caliper ]
=> [ Brake Disc ]
=> [ Brake Disc, Replacing ]
=> [ Front Cover Plate ]
• Always install complete repair set
• After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position.
• Make sure the brakes are working correctly before driving the vehicle for the first time.
• When siphoning brake fluid, always use a bleeder bottle that is used exclusively for brake fluid. Brake fluid is poisonous. NEVER siphon brake fluid with your mouth!
• Check brake caliper for ease of movement by moving it sideways.
Brake Pads
Special tools, testers and auxiliary items required
• 9 mm socket (T50036)
• Torque wrench (V.A.G 1332)
• Piston resetting tool (T10145)
Removing
• When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven!
• Pay attention the arrow on the brake rotor showing the direction of travel and to the left and right installed location when installing the brake rotors.
- Raise vehicle.
- Remove wheels.
- Disconnect the connector for the brake pad wear display - arrow -.
- Release the connector from the mount while turning it 90° at the same time.
- Remove the connector from the bracket.
- Unhook brake line from retainer.
- Remove the screw - 8 - for the balance spring and cover.
• Spring is tensioned, protect with a glove or cloth.
- Remove the balance spring - 10 - and cover - 9 -.
- Remove - 17 - caps.
• Remove the guide pin - 16 - and the 9 mm Allen screw with the (T50036).
- Remove the guide pin - 16 - from the brake caliper.
- Remove brake caliper housing and hang it up so that the weight of the brake caliper does not burden or damage the brake hose.
- Remove the outer brake pad from the brake caliper.
- Remove the inner brake pad and the wire for the brake pad wear display from the brake caliper. When doing this, push the wire through the brake caliper.
• The brake pad with wear indicator sits inside.
• The brake carrier must be removed in order to replace the brake discs.
• Clean brake caliper with mineral spirits exclusively.
Installing
• Replace any damaged guide pins. Allocation, refer to the Electronic Parts Catalog (ETKA).
- Press both pistons back.
• Press piston back into caliper housing using resetting tool before inserting new brake pads. Before pushing back the piston, siphon some of the brake fluid out of the brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.
Brake fluid is poisonous. NEVER siphon brake fluid with your mouth!
Remove any film on the back of the pad before installing.
- Install the clip for the brake pad wear display into the inner brake pad.
- Install the contact in the clip - direction of arrow -.
• Make sure the contact for the brake pad wear display fits correctly in the clip inside the inner brake pad.
- Install the inner brake pad and the wire for the brake pad wear display in the brake caliper. When doing this, push the wire through the brake caliper.
- Install the outer brake pad - 2 - in the brake caliper.
• Make sure the contact for the brake pad wear display fits correctly in the clip inside the inner brake pad.
- Slide the brake caliper with the brake pads installed over the brake rotor.
• Make sure the brake hose is routed correctly. Make sure the brake hose is not blocked, bent or rubbing against the vehicle.
- Push the guide pin - 16 - through the brake caliper.
• Make sure the seals for the guide pins are not damaged.
• Make sure the seal is correctly installed.
- Attach the brake caliper to the brake carrier with both guide pins (55 Nm).
- Install both caps - 17 -.
• Make sure the brake hose is not twisted.
- Install the balance spring - 10 - and cover - 9 - in the brake caliper housing.
- Install the bolt - 8 - and tighten.
• Make sure the cover and balance spring are installed correctly.
• The tips of the balance spring fit into the brake caliper.
• The tip of the balance spring fits under the cover.
- Install the brake line in the bracket.
- Connect wear indicator connector.
- Install the electrical connection for the brake pad wear display in the bracket.
- Install wheels.
Wheel bolt tightening specifications, refer to => Wheel
and Tire Guide Specifications.
- Lower vehicle.
- Check brake fluid level, and fill if necessary.
• After installing, press the brake pedal several times firmly to properly seat brake pads in their normal operating position.
• Make sure the brakes are working correctly before driving the vehicle for the first time.
Brake Pad Wear Display Wire
Removing
- Raise vehicle.
- Remove wheels.
- Disconnect the connector for the brake pad wear display - arrow -.
- Release the connector from the mount while turning it 90° at the same time.
- Remove the connector from the bracket.
- Remove the brake pad wear display contact form the clip inside the inner brake pad.
- Remove the clip from the inner brake pad.
Installing
- Install the clip for the brake pad wear display into the inner brake pad.
- Install the contact in the clip - direction of arrow -.
• Make sure the contact for the brake pad wear display fits correctly in the clip inside the inner brake pad.
- Connect wear indicator connector.
- Install the electrical connection for the brake pad wear display in the bracket.
- Install wheels.
Wheel bolt tightening specifications, refer to => Wheel
and Tire Guide Specifications.
- Lower vehicle.
Brake Caliper with Brake Carrier
Special tools, testers and auxiliary items required
• Torque wrench (V.A.G 1332)
Removing
- Raise vehicle.
- Remove wheels.
- Disconnect the connector for the brake pad wear display - arrow -.
- Release the connector from the mount while turning it 90° at the same time.
- Remove the connector from the bracket.
- Unhook brake line from retainer
• Pushing on the brake pads lightly with pliers makes it easier to remove the brake caliper from the brake rotor. Be careful not do damage the paint on the brake caliper.
- Push the brake pad back with pliers.
- Remove bolts - 13 -.
- Remove the brake caliper - 7 - with the brake carrier - 12 - and tie them up so that the weight does not rest on or damage the brake hose.
Installing
• Replace the bolts - 13 -. Allocation, refer to the Electronic Parts Catalog (ETKA).
- Push the brake caliper - 7 - with the brake carrier - 12 - and the brake pads installed carefully over the brake rotor.
• Make sure the brake hose is routed correctly. Make sure the brake hose is not blocked, bent or rubbing against the vehicle.
- Tighten the brake carrier with new bolts - 13 -.
- Install the brake line in the bracket.
- Connect wear indicator connector.
• Make sure the contact for the brake pad wear display fits correctly in the clip inside the inner brake pad.
- Install the electrical connection for the brake pad wear display in the bracket.
- Install wheels.
Wheel bolt tightening specifications, refer to => Wheel
and Tire Guide Specifications.
- Lower vehicle.
- Check brake fluid level, and fill if necessary.
• After installing, press the brake pedal several times firmly to properly seat brake pads in their normal operating position.
• Make sure the brakes are working correctly before driving the vehicle for the first time.
Brake Caliper
• Install on one axle on brake calipers from the same manufacturer and with the same quality
Special tools, testers and auxiliary items required
• Torque wrench (V.A.G 1332)
• Brake pedal actuator (V.A.G 1869/2)
• 9 mm socket (T50036)
• Piston resetting tool (T10145)
Removing
- Insert the (V.A.G 1869/2) between the brake pedal and driver seat by pressing the brake pedal down at least 60 mm.
- Raise vehicle.
- Remove wheels.
- Connect the hose from a bleeder bottle to a brake caliper brake caliper bleeder screw - 2 -.
- Open a brake caliper bleeder screw on the front brake caliper to reduce the pressure from the brake system.
- Close the bleeder screw.
• Do not remove (V.A.G 1869/2).
- Remove the brake line - 18 - from brake caliper.
- Remove brake pads. Refer to => [ Brake Pads ].
• When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven!
• The brake disc is secured with a bolt.
Installing
- Install brake pads. Refer to => [ Brake Pads ].
• Replace any damaged guide pins. Allocation, refer to the Electronic Parts Catalog (ETKA).
• Make sure the brake hose is routed correctly. Make sure the brake hose is not blocked, bent or rubbing against the vehicle.
- Install the brake line - 18 - in the brake caliper and tighten it to 19 Nm.
- Install the brake line in the bracket.
- Connect wear indicator connector.
- Install the electrical connection for the brake pad wear display in the bracket.
• Make sure the contact for the brake pad wear display fits correctly in the clip inside the inner brake pad.
- Bleed brake system. Refer to => [ Brake System, Bleeding ] Service and Repair.
- Install wheels.
Wheel bolt tightening specifications, refer to => Wheel
and Tire Guide Specifications.
- Lower vehicle.
- Check brake fluid level, and fill if necessary.
• After installing, press the brake pedal several times firmly to properly seat brake pads in their normal operating position.
• Make sure the brakes are working correctly before driving the vehicle for the first time.
Brake Disc
Special tools, testers and auxiliary items required
• Torque wrench (V.A.G 1332)
• Torque wrench (V.A.G 1331)
• Pay attention the arrow on the brake rotor showing the direction of travel and to the left and right installed location when installing the brake discs.
Removing
- Raise vehicle.
- Remove wheels.
- Remove the brake caliper. Refer to => [ Brake Caliper with Brake Carrier ].
- Remove the screw - 19 - from the brake disc.
• Pushing on the brake pads lightly with pliers makes it easier to remove the brake caliper from the brake rotor. Be careful not do damage the paint on the brake caliper.
- Remove the brake rotor.
- Clean the brake rotor and the wheel hub before installing the brake disc.
Installing
• Replace the bolts. Allocation, refer to the Electronic Parts Catalog (ETKA).
• Pay attention to the left or right installed locations when installing the brake discs.
- Place the brake disc on the hub.
• Do not tilt the brake disc when mounting it on the wheel hub.
- Install the bolt - 19 - and tighten it to 9 Nm.
- Install the brake caliper with brake carrier. Refer to => [ Brake Caliper with Brake Carrier ].
- Install the brake line in the bracket.
• Make sure the brake hose is routed correctly. Make sure the brake hose is not blocked, bent or rubbing against the vehicle.
- Connect wear indicator connector.
• Make sure the contact for the brake pad wear display fits correctly in the clip inside the inner brake pad.
- Install the electrical connection for the brake pad wear display in the bracket.
- Install wheels.
Wheel bolt tightening specifications, refer to => Wheel
and Tire Guide Specifications.
- Lower vehicle.
- Check brake fluid level, and fill if necessary.
• After installing, press the brake pedal several times firmly to properly seat brake pads in their normal operating position.
• Make sure the brakes are working correctly before driving the vehicle for the first time.
Brake Disc, Replacing
Special tools, testers and auxiliary items required
• 9 mm socket (T50036)
• Torque wrench (V.A.G 1332)
• Torque wrench (V.A.G 1331)
• Piston resetting tool (T10145)
Removing
• Pay attention to the left or right installed locations when installing the brake rotors.
- Raise vehicle.
- Remove wheels.
- Disconnect the connector for the brake pad wear display - arrow -.
- Release the connector from the mount while turning it 90° at the same time.
- Remove the connector from the bracket.
- Unhook brake line from retainer.
- Remove brake pads. Refer to => [ Brake Pads ].
- Remove the bolts - 13 - and then remove the brake carrier.
- Remove bolt - 19 -.
- Remove the brake disc.
- Clean the brake disc and the wheel hub before installing the brake disc.
Installing
• Replace the bolts. Allocation, refer to the Electronic Parts Catalog (ETKA).
• Pay attention the arrow on the brake disc showing the direction of travel and to the left and right installed location when installing the brake discs.
- Place the brake disc on the hub.
• Do not tilt the brake disc when mounting it on the wheel hub.
- Install the screw - 19 - and tighten it to 9 Nm.
- Install the brake carrier - 12 -.
- Tighten the brake carrier with new bolts - 13 -.
- Install brake pads. Refer to => [ Brake Pads ].
• Make sure the contact for the brake pad wear display fits correctly in the clip inside the inner brake pad.
- Install the brake line in the bracket.
• Make sure the brake hose is routed correctly. Make sure the brake hose is not blocked, bent or rubbing against the vehicle.
- Connect wear indicator connector.
- Install the electrical connection for the brake pad wear display in the bracket.
- Install wheels.
Wheel bolt tightening specifications, refer to => Wheel
and Tire Guide Specifications.
- Lower vehicle.
- Check brake fluid level, and fill if necessary.
• After installing, press the brake pedal several times firmly to properly seat brake pads in their normal operating position.
• Make sure the brakes are working correctly before driving the vehicle for the first time.
Front Cover Plate
Removing
- Raise vehicle.
- Remove wheels.
- Remove the brake disc. Refer to => [ Brake Disc ].
- Remove the cover plate bolts - arrows -.
- Remove cover plate - 1 -.
Installing
- Mount the cover plate - 1 -.
- Install the bolts - arrows - and tighten to 10 Nm.
- Install the brake disc. Refer to => [ Brake Disc ].
• Make sure the brake hose is routed correctly. Make sure the brake hose is not blocked, bent or rubbing against the vehicle.
• After installing, press the brake pedal several times firmly to properly seat brake pads in their normal operating position.
• Make sure the brakes are working correctly before driving the vehicle for the first time.