Assembly Overview

Brake Caliper Assembly Overview

• After replacing the brake pads, press the brake pedal firmly several times with the vehicle stationary so that the brake pads are properly seated in their normal operating position.

• Use the brake charger/bleeder unit (VAS 5234) or extraction device (VAG 1869/4) to extract brake fluid from the brake fluid reservoir.

• Before removing the brake caliper or disconnecting the brake hose, the brake pedal actuator (VAG 1869/2) must be inserted (this dissipates pressure).





1 Wheel speed sensor

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

2 Bolt, 8 Nm

3 Bolt, 90 Nm + 90°

• Always replace after removal.

4 Wheel bearing housing

5 Cover plate

6 Torx bolt, 12 Nm

7 Wheel bearing/hub unit

8 Brake disc

• 286 mm diameter.

• Thickness: 12 mm.

• Wear limit: 10 mm.

• Always replace pads on both sides of axle if worn.

• Remove brake caliper before removing.

9 Phillips head screw, 4 Nm

10 Bolt

• Only on Front Wheel Drive (FWD).

11 Brake pads

• Thickness: 11 mm without backing plate.

• Wear limit: 2 mm without backing plate.

• Checking thickness, refer to => 18.1.

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

• Removing and installing, refer to => [ Brake Pads ] Service and Repair.

12 Brake carrier with 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.

13 Anti rattle spring

• Always replace when pads are replaced.

14 Brake caliper

• Do not remove brake hose when replacing brake pad.

• Removing and installing, refer to => [ Brake Caliper ] Removal and Replacement.

• Disassembly, refer to => [ Brake Caliper Assembly Overview ] Description and Operation.

• 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 Hex bolt, self locking, 35 Nm

• Replace

18 Parking brake cable

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

19 Spring clamp

20 Brake hose