Brake Caliper

Brake Caliper

Special tools, testers and auxiliary items required

• Torque Wrench (V.A.G 1331)

• Brake Pedal Actuator (V.A.G 1869/2)

• Vehicle Diagnostic, Test and Information System (VAS 5051)

• Diagnostic Cable (VAS 5051/1) or (VAS 5051/3)

Removing

Work procedure applies only for replacing or when performing subsequent service work on brake caliper.

• Do not disconnect the connectors from the parking brake motors.

- Remove wheels.

The pistons of the parking brake must be driven back using the (VAS 5051).

Before pressing piston back, draw off brake fluid from reservoir using a bleeder bottle. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.

- (VAS 5051), connecting and selecting functions. Refer to => [ VAS 5051, Connecting and Selecting Functions ] Testing and Inspection.

- Select the electro-mechanical parking brake and the function moving piston of parking brake motor out and in.

- Drive the pistons back using the (VAS 5051).

- Remove the parking brake motor without disconnecting the connector.

- Connect bleeder bottle bleeder hose to brake caliper bleeder valve and then open bleeder valve.

- Insert (V.A.G 1869/2).

- Close bleeder valve and remove bleeder bottle.

- Remove the brake line from the brake hose and brake caliper.

- Remove both bolts from brake caliper, counterhold on guide pin when doing this.

- Pull off brake caliper from brake carrier.

Installing

• Brake pads sit in retaining springs on the brake carrier.

- Secure brake caliper on brake carrier using new self-locking bolts.

Ring groove and contact surface of parking brake motor must be clean.

- Install new seal.

- Rotate the spindle back slightly with an 8 mm multi-point socket until the parking brake motor can be positioned correctly.

- Carefully set the parking brake motor in place, paying attention to the seat of the seal.

- Rotate the parking brake motor until the bolt hole and threads are aligned.

• Make sure that the parking brake motor is seated flush against the brake caliper. Do not, under any circumstances, pull the parking brake motor against the brake caliper using the bolts.

- Set the TORX(R) bolts in place by hand and then tighten.

- Screw brake line on brake caliper.

- Bleed brake system. Refer to => [ Brake System, Bleeding ] Brake System, Bleeding.

After driving the pistons out with the (VAS 5051), a basic setting of the brake system must be performed.

- Perform the basic setting of the brake system with the (VAS 5051).

- Install wheels.

Tightening specification for wheel bolts.

• Check brake fluid level.