FS III Brake Caliper, Servicing

Special tools and equipment
^ VAG 1331 Torque wrench or equivalent
^ VAG 1410 Torque wrench or equivalent
^ VAG 1869/2 Brake pedal depressor or equivalent

Notes:
^ After replacing brake pads, depress the brake pedal firmly several times with the vehicle stationary so that the brake pads are properly seated in their normal operating position.





^ To draw off brake fluid from the reservoir, use a bleeder bottle, which is used only for brake fluid. Brake fluid is poisonous and must not be siphoned out by mouth!

^ Before removing a caliper or disconnecting a brake hose to the caliper, install the brake pedal depressor VAG 1869 or equivalent.
1 Screw, 4 Nm (35 inch lbs.)
2 Brake disc
^ Thickness when new: 22 mm
^ Wear limit: 20 mm (0.787 inch)
^ When worn always replace on both sides
^ Remove brake caliper prior to removing brake disc
^ Never remove brake discs from hub by force. If necessary use penetrating fluid, otherwise brake discs can be damaged.
3 Exterior brake pad
^ Thickness: 14 mm
^ Always replace brake pads on same axle on both sides of vehicle at same time
4 Interior brake pad
^ Thickness: 14 mm
^ Always replace brake pad on front left axle
^ From 2000 left wheel brake pad has pad wear indicator
5 - Brake caliper
^ When replacing brake pads do not disconnect brake hose to caliper
^ Removing:
- Remove brake pads -3- and -4-
- Install brake pedal depressor VAG 1869/2 or equivalent
- Disconnect brake hose connection -8- from brake caliper
^ Installing
- Install brake pads -3- and -4-
- Connect brake hose connector -8- to caliper
- Remove brake pedal depressor
- Bleed brake system
6 Guide pins, 28 Nm (21 ft. lbs.)
7 Protective cap
^ Take off
8 Brake hose and union with banjo bolt, 35 Nm (26 ft. lbs.)
^ Always replace copper washer when the brake hose and union with banjo bolt are disassembled
9 Wheel bearing housing
10 Pad wear sensor connector bracket
^ It is not necessary to remove harness connector from connector bracket when replacing brake pad with pad wear sensor
11 Hex socket head bolt, 8 Nm (70 inch lbs.)
12 ABS wheel speed sensor
^ Before inserting sensor, clean mounting hole inner surface and coat speed sensor with lubricant G 000 650
13 Splash shield
14 Hex bolt, 10 Nm (7 ft. lbs.)
15 Wheel bearing
^ Replace each time if removed
^ Pressing out and in
16 Circlip
17 Wheel hub with ABS wheel speed sensor rotor
^ Pressing out and in