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 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 in any case be siphoned out by mouth using a hose!
^ 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
^ Always replace both sides
^ Wear limit: 7 mm (0.276 inch) including backing plate
4. Retaining spring
^ Insert in both brake caliper housing drillings
5. Brake carrier
6. Brake caliper housing
^ Do not disconnect brake hose when changing brake pads
- Remove brake pads
- Install brake pedal depressor VAG 1869/2 or equivalent
- Unscrew brake hose from brake caliper
- Install brake pads
- Connect brake hose on brake caliper
- Remove brake pedal depressor VAG 1869/2 or equivalent
- Bleed brake system
7. Guide pins, 28 Nm (21 ft. lbs.)
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 (94 ft. lbs.)
11. Wheel bearing housing
12. Hex socket head bolt, 8 Nm (71 inch lbs.)
13. ABS speed sensor
^ Before inserting sensor, clean mounting hole inner surface and coat with lubricant G 000 650
14. Splash plate
15. Hex bolt, 10 Nm (88.5 inch lbs.)
16. Wheel bearing
17. Circlip
18. Wheel hub with rotor
19. Brake pads
^ With wear indicator
- Warning lamp lights up on instrument panel when wear limit is reached (limit: 2 to 3 mm, 0.079 to 0.118 inch)
^ Thickness 14 mm (0.551 inch)
^ Checking thickness
Refer to Maintenance Manual; Work sequences; Front and rear brake pads/linings; Checking thickness
^ Always replace both sides
^ Wear limit: 7 mm (0.276 inch) including backing plate
20. Connector
^ Take out of retainer -item 21. when changing brake pads
21. Retainer
22. Bolt