Assembly Overview
Brake Caliper Assembly Overview
• After replacing 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).
FN3 Caliper, 15 Inch
1 Phillips/Torx screw, 4 Nm
2 Brake disc
• Internally vented, 288 mm diameter.
• Thickness: 25 mm.
• Wear limit: 22 mm.
• Must always be replaced together on both sides of axle.
• Remove the brake caliper and brake carrier before removing.
3 Brake pads
• Thickness: 14 mm without backing plate.
• With wear indicator.
• When wear limit is reached (limit: approximately 4 mm), the warning lamp lights up in instrument cluster.
• 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.
4 Retaining spring
• Insert in both holes of brake caliper.
5 Brake carrier
• Bolt to wheel bearing housing.
6 Brake caliper
• Do not remove brake hose when replacing brake pads.
• Removing and installing, refer to => [ Brake Caliper ] Removal and Replacement.
• Disassembly, refer to => [ Brake Caliper Assembly Overview ] Description and Operation.
7 Guide pins, 30 Nm
8 Cap
• Remove
9 Brake hose with banjo fitting and union bolt, 35 Nm
10 Ribbed bolt, 190 Nm
• Clean if reusing.
11 Bolt
12 Bracket
13 Wheel bearing housing
• With bolted brake carrier
14 Wheel speed sensor
• Before inserting sensor, clean inner surface of bore and coat with hot bolt paste (G 052 112 A3).
15 Bolt, 8 Nm
16 Cover plate
17 Hex head/Torx bolt, 12 Nm
• Hex head bolt M6 x 10 changed from Torx bolt M6 x 12.
• Replace hex head bolt with a hex head bolt and a Torx bolt with Torx bolt.
18 Wheel bearing/hub unit
• The Anti-lock Brake System (ABS) sensor ring is installed in the wheel bearing.
FN3 Caliper, 16 Inch
1 Torx bolt, 12 Nm
2 Brake disc
• Internally vented, 312 mm diameter.
• Thickness: 25 mm.
• Wear limit: 22 mm.
• Must always be replaced together on both sides of axle.
• Remove the brake caliper and brake carrier before removing.
3 Torx bolt, 4 Nm
4 Brake pads
• Thickness: 14 mm without backing plate.
• With wear indicator.
• When wear limit is reached (limit: approximately 4 mm), the warning lamp lights up in instrument cluster.
• 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.
5 Retaining spring
• Insert in both holes of brake caliper.
6 Brake carrier
• Bolt to wheel bearing housing.
7 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.
8 Guide pins, 30 Nm
9 Cap
• Remove
10 Brake hose with banjo fitting and union bolt, 35 Nm
11 Guide pins, 30 Nm
12 Cap
• Remove
13 Bolt
14 Bracket
15 Ribbed bolt, 190 Nm
• Clean if reusing.
16 Wheel bearing housing
• With bolted brake carrier.
17 Wheel speed sensor
• Before inserting sensor, clean inner surface of bore hole and coat with hot bolt paste (G 052 112 A3).
18 Bolt, 8 Nm
19 Wheel bearing/hub unit
• The Anti-lock Brake System (ABS) sensor ring is installed in the wheel bearing.
20 Cover plate