Disc Brake System: Service and Repair

Rear Brakes, CII 41 Assembly Overview, AWD

• 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.

• Use Brake Charger/Bleeder Unit (VAS 5234) or Extraction Device (V.A.G 1869/4) to extract brake fluid from brake fluid reservoir.

• Before removing brake caliper or disconnecting brake hose, Brake Pedal Depressor (V.A.G 1869/2) must be inserted (this dissipates pressure).





1 Bolt, 90 Nm + 90°

• Always replace after removal.

2 ABS Wheel Speed Sensor

• Before inserting sensor, clean inner surface of bore hole and coat with hot bolt paste (G 052 112 A3).

3 Bolt, 8 Nm

4 Wheel Bearing Housing

5 Cover Plate

6 Bolt, 12 Nm

• M6 x 12

7 Wheel Bearing/Hub Unit

8 Brake Disc

• 15 inches: 256 mm.

• Thickness 15 inches: 12 mm.

• Wear limit 15 inch: 10 mm.

• Always replace pads on both sides if worn.

• Remove brake caliper before removing.

9 Bolt

10 Bolt, 4 Nm

11 Brake Pads

• Thickness 11 mm without backing plate.

• Wear limit: 2 mm without backing plate.

• Checking thickness, maintenance, refer to => Front and Rear Brake Pads: Check Thickness.

• Must always be replaced together on both sides of vehicle.

• Removal and installation, refer to => [ Rear Brake Pads, with Brake Caliper CII 41, AWD ] Rear Brake Pads, with Brake Caliper CII 41, AWD.

12 Brake Carrier with Different Guide Pins and Protective Cap

• Supplied as pre-assembled replacement part with sufficient grease on guide pins.

• If protective caps or guide pins are damaged, install repair kit. Use supplied grease packet to lubricate guide pins.

• Assembly guide, refer to => [ Installation Instructions, Brake Carrier: ]

13 Anti-Rattle Spring

• Always replace when pads are replaced.

14 Brake Caliper

• Do not unscrew brake hose when replacing brake pad.

• Removal and installation, refer to => [ Rear Brake Caliper CII 41, AWD ] Rear Brake Caliper CII 41, AWD.

• Servicing, refer to => [ Rear Brake Caliper CII 41 Assembly Overview ] Rear Brake Caliper CII 41 Assembly Overview.

• After servicing or replacing, parking brake cable must be adjusted first.

• Adjusting parking brake, refer to => [ Parking Brake, Adjusting ] Adjustments.

15 Hose Retainer

16 Brake Line, 14 Nm

17 Bolt, 35 Nm

• Self-locking

• Always replace after removal.

18 Parking Brake Cable

• Adjusting parking brake, refer to => [ Parking Brake, Adjusting ] Adjustments.

• Removal and installation, refer to => [ Parking Brake Cable ] Service and Repair.

19 Spring Clamp

20 Brake Hose

Installation Instructions, Brake Carrier:





1. Short guide pins with stepping - arrows -, inlet side.

2. Longer guide pins, outgoing.

3. Vibration dampener, outgoing.