Front Brakes, PR-1LN and 1LP
Front Brakes, PR-1LN and 1LP
=> [ Brake Pads ]
=> [ Brake Pad Wear Display ]
=> [ Brake Caliper, from Wheel Bearing Housing ]
=> [ 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
• Torque wrench (V.A.G 1332)
• Piston resetting tool (T10145)
• When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven!
Removing
- 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 caliper bolts - 11 -.
Remove only these bolts - 11 - for removing the brake caliper.
• Do not loosen the brake hose.
The brake caliper may not be removed from the brake carrier. The radial bolted multipoint head cap screw must never be loosened.
- Pull the brake caliper from the brake disc.
- Hang the brake caliper on the body using a suitable wire.
Do not let the brake caliper hang on the brake hose.
- Pry the brake pads out of the guide pins in the brake caliper using a commercially available screwdriver - arrows -. Be careful not to damage the dust caps on the brake pistons.
Do not loosen the four guide pins for the brake pads inside the brake caliper.
- Remove the brake pads from the balance spring.
- Remove the brake pad wear display wire and the clip from the brake pad.
- Pry the balance spring - 8 - out of the brake caliper with a screwdriver.
Installing
• Use new bolts.
- Clean brake caliper.
• Only use commercially available brake cleaner to clean the brake caliper housing.
Before pressing pistons into cylinder using piston resetting tool, brake fluid must be extracted from 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!
- Push back the piston using the (T10145).
- Remove any protective film from the brake pad backing plate.
- Install the balance spring - 8 - in the brake caliper.
• Make sure the balance spring - 8 - fits correctly.
• The balance spring must fit completely inside the brake caliper so that the brake pads sit correctly in the guide pins.
- Install brake pads inside the brake caliper and push them all the way over the 4 guide pins - arrows -.
All brake pads must fit correctly in the bolts.
- Mount the brake caliper with 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 caliper with the new bolts - 11 -.
- Install the clip for the brake pad wear contact in 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.
- Connect the connector for the brake pad wear display.
- Install wheels.
Wheel bolt tightening specifications, refer to => Wheel and Tire Guide Specifications.
• After replacing brake pads and before moving vehicle, always depress brake pedal several times firmly to properly seat brake pads in their normal operating position.
• Check brake fluid level after replacing brake pad.
• Make sure the brakes are working correctly before driving the vehicle for the first time.
Brake Pad Wear Display
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 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 contact in 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, from Wheel Bearing Housing
Special tools, testers and auxiliary items required
• Torque wrench (V.A.G 1332)
• Piston resetting tool (T10145)
Removing
- Remove wheels.
• When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven!
Removing
- 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.
• 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.
- Press the brake pads into the brake caliper with pliers.
- Remove the brake caliper bolts - 11 -.
Remove only these bolts - 11 - for removing the brake caliper.
• Do not loosen the brake hose.
The brake caliper may not be removed from the brake carrier. The radial bolted multipoint head cap screw must never be loosened.
- Pull the brake caliper from the brake disc.
- Hang the brake caliper on the body using a suitable wire.
Do not let the brake caliper hang on the brake hose.
Installing
Replace the bolts - 11 -. Allocation, refer to the Electronic Parts Catalog.
- Slide the brake caliper - 7 - with 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 caliper with the new bolts - 11 -.
• 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.
- 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 Caliper
Special tools, testers and auxiliary items required
• Torque wrench (V.A.G 1332)
• Brake pedal actuator (V.A.G 1869/2)
• Piston resetting tool (T10145)
• Install on one axle on brake calipers from the same manufacturer and with the same quality.
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 - 12 -.
- 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 - 9 - 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.
The brake caliper may not be removed from the brake carrier. The radial bolted multipoint head cap screw must never be loosened.
Installing
• Use new bolts.
- Install brake pads. Refer to => [ Brake Pads ].
• 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
Removing
• Observe the direction of rotation when installing brake disc (arrow on brake disc) and installed location (left or right).
- 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.
- Disengage the brake line - arrow - from it mounting.
- Remove bolts - 11 -.
- Remove the brake caliper. Refer to => [ Brake Caliper, from Wheel Bearing Housing ].
- Hang the brake caliper on the body using a suitable wire.
Do not let the brake caliper hang on the brake hose.
The brake caliper may not be removed from the brake carrier. The radial bolted multipoint head cap screw must never be loosened.
- Remove the brake disc bolt - 5 -.
- Remove the brake disc.
- Clean the brake disc and the wheel hub before installing the brake disc.
Installing
• Replace the bolts - 11 -. Allocation, refer to the Electronic Parts Catalog.
• 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 and tighten the brake disc bolt.
- Install the brake caliper. Refer to => [ Brake Caliper, from Wheel Bearing Housing ].
• 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 caliper with the new bolts - 11 -.
• 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.
- 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 Disc, Replacing
Removing
• Observe the direction of rotation when installing brake disc (arrow on brake disc) and installed location (left or right).
- 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 ] Front Brakes, PR-1LL and 1LM.
- Hang the brake caliper on the body using a suitable wire.
Do not let the brake caliper hang on the brake hose.
The brake caliper may not be removed from the brake carrier. The radial bolted multipoint head cap screw must never be loosened.
- Remove the brake disc bolt.
- 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 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 and tighten the brake disc bolt.
- Install brake pads. Refer to => [ Brake Pads ] Front Brakes, PR-1LL and 1LM.
- Slide the brake caliper with the brake pads installed over the brake disc.
• 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 caliper with the new bolts.
• 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.
- 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.