Front Brakes, FS III Brake Caliper, Assembly Overview

Front brakes, FS III brake caliper, assembly overview





Special tools and equipment

^ VAG 1331 Torque wrench
^ VAG 1410 Torque wrench
^ VAG 1869/2 Brake pedal depressor

Special tools and equipment





^ VAS 5234 Brake filler and bleeder unit





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.
^ Install brake pedal depressor VAG 1869/2 before removing a brake caliper or disconnecting a brake hose.
^ Tighten wheel bolts.

1- Phillips-head screw, 4 Nm (35 in. lb)





2- Brake disc
^ Thickness 22 mm (0.866 in.)
^ Wear limit: 19 mm (0.748 in.)
^ When worn always replace both sides
^ Remove brake caliper prior to removing
^ Never remove brake discs from hub by force. If necessary use penetrating fluid, otherwise brake discs can be damaged.
3- Brake pads
^ Thickness 19.7 mm (0.775 in.) including backing plate
^ Always replace both sides
^ Wear limit: 7 mm (0.276 in.) including back plate





4- Brake caliper
^ Do not disconnect brake hose when changing brake pads
5- Guide pins, 30 Nm (22.1 ft. lb)





6- Protective cap
^ Remove
7- Brake hose with banjo union and banjo bolt, 35 Nm (26 ft. lb)
^ Always use new sealing washers
8- Wheel bearing housing
9- Hex socket head bolt, 8 Nm (71 in. lb)
10- ABS speed sensor
^ Before inserting sensor, clean mounting hole inner surface and coat with lubricating paste G 000 650
11- Splash plate
12- Hex bolt, 10 Nm (89 in. lb)





13- Wheel bearing
^ Replace each time after removing
14- Circlip
15- Wheel hub with rotor





16- 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 in.)
^ Thickness 19.7 mm (0.775 in.) including backing plate
^ Always Replace both sides
^ Wear limit: 7 mm (0.276 in.) including back plate
17- Connector
^ Remove from bracket -item 18- when changing pads
18- Bracket
19- Bolt