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 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).

I - Front Wheel Drive (FWD) overview

II - All Wheel Drive (AWD) differences





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 Hex head bolt, 9 Nm/Torx bolt12 Nm

• Hex head bolt M6 x 10 changed from Torx bolt M6 x 12.

• Replace the hex head bolt with a hex head bolt and the Torx bolt with a Torx bolt.

7 Wheel bearing/hub unit

8 Brake disc

• 15 inches: 260 mm diameter, 16 inches: 286 mm diameter and 17 inches: 310 mm diameter.

• Thickness: 15 and 16 inches: 12 mm, 17 inches: 22 mm.

• Wear limit: 15 and 16 inches: 10 mm, 17 inches: 20 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 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 different 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.

• Assembly guide, refer to => [ Assembly Guide, Brake Carrier CII 41 15 Inch
from 08.04 ]

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

Assembly Guide, Brake Carrier CII 41 15 Inch from 08.04





1. Short guide pins with stepping - arrows -, inlet side.

2. Longer guide pins, outgoing.

3. Vibration dampener, outgoing.