Front Brakes, Fn 3 Brake Caliper, Servicing

Front brakes, FN 3 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

Note:
^ 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.
^ To draw off brake fluid from the reservoir, use brake filler and bleeder unit VAS 5234 or extraction unit VAG 1869/4.
^ Install brake pedal depressor VAG 1869/2 before removing a brake caliper or disconnecting a brake hose.

1. Phillips-head screw, 4 Nm (35 inch lbs.)
2. Brake disc
- Thickness 25 mm (0.984 inch)
- Wear limit: 22 mm (0.866 inch)
- When worn always replace both sides
3. Brake pads Thickness 14 mm (0.551 inch) Checking thickness
- Always replace both sides
- Removing and installing
- Wear limit: 7 mm (0.276 inch) including back plate
4. Retaining spring
- Insert in both brake caliper housing holes
5. Brake carrier
6. Brake caliper housing
- Do not disconnect brake hose when changing brake pads
- Removing:
- Remove brake pads -item 3.
- Install brake pedal depressor VAG 1869/2
- Unscrew brake hose -item 9 from brake caliper
- Installing:
- Install brake pads -item 3.
- Install brake hose -item 9 on brake caliper
- Remove brake pedal depressor VAG 1869/2
- Bleed brake system Mark 60
- Servicing
7. Guide pins, 28 Nm (21 ft. lbs.)
- Removing and installing
8. Protective cap
- Take off
9. Brake hose with banjo union and banjo bolt, 35 Nm (26 ft. lbs.)
10. Ribbed combi bolt, 125 Nm (92 ft. lbs.)
11. Wheel bearing housing
12. Hex socket head bolt, 8 Nm (71 ft. lbs.)
13. ABS speed sensor
- Before inserting sensor, clean mounting hole inner surface and coat with lubricating paste G 000 650
14. Splash plate
15. Hex bolt, 10 Nm (7.4 ft. lbs.)
16. Wheel bearing
- Replace each time after removing
- Pressing out and in
17. Circlip
18. Wheel hub with rotor
- Pressing out and in
19. Brake pads
- With wear indicator
- Warning lamp lights up on instrument panel when wear limit is reached (limit: 2 to 3 mm; 0.0787 to 0.118 inch).
- Thickness 14 mm (0.551 inch)
- Checking thickness
- Always replace both sides
- Removing and installing from
- Wear limit: 7 mm (0.276 inch) including back plate
20. Connector
- Remove from bracket -item 21 when changing brake pads
21. Retainer
22. Bolt