Mechanical Components
Caliper Assembly Overview
• After replacing the brake pads, press the brake pedal firmly several times to properly seat the brake pads in their normal operating position.
• Use the brake charger/bleeder unit (VAS 5234) or (VAG 1869/4) to extract brake fluid from the brake fluid reservoir.
• Before removing the brake caliper or disconnecting the brake line, the brake pedal actuator (VAG 1869/2) must be inserted (this dissipates pressure).
15 Inch Caliper
1 Bolt, 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 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 the instrument cluster.
• Wear limit: 2 mm without backing plate.
• Checking thickness.
• 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 the brake caliper.
5 Brake carrier
• Bolts to the wheel bearing housing.
6 Brake caliper
• Do not remove brake hose when replacing brake pads.
• Removing and installing, refer to --> [ Brake Caliper ] Brake Caliper.
• Assembly overview, refer to --> [ Front Bake Caliper Assembly Overview ] Brake Caliper Assembly Overview.
7 Guide pins, 30 Nm
8 Cap
• Remove
9 Brake hose with ring connection and banjo fitting, 35 Nm
10 Bolt, ribbed, 190 Nm
• Clean if reusing.
11 Bolt
12 Bracket
13 Wheel bearing housing
• With bolted brake carrier.
14 Wheel speed sensor
• Before installing the sensor, clean the inner surface of the bore and coat with hot bolt paste (G 052 112 A3).
15 Bolt, 8 Nm
16 Cover plate
17 Hex/Torx bolt, 12 Nm
• M6 x 10 hex bolt, changed from a M6 x 12 Torx bolt.
• Replace a hex bolt with a hex bolt and a Torx bolt with a Torx screw.
18 Wheel bearing/hub unit
• The ABS sensor ring is installed in the wheel bearing.
16 Inch Caliper
1 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 brake caliper and brake carrier before removing.
3 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 the instrument cluster.
• Wear limit: 2 mm without backing plate.
• Checking thickness.
• 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 the brake caliper.
6 Brake carrier
• Bolted to the wheel bearing housing.
7 Brake caliper
• Do not remove brake line when replacing brake pads.
• Removing and installing, refer to --> [ Brake Caliper ] Brake Caliper.
• Assembly overview, refer to --> [ Front Bake Caliper Assembly Overview ] Brake Caliper Assembly Overview.
8 Guide pins, 30 Nm
9 Cap
• Remove
10 Brake line with ring connection and banjo fitting, 35 Nm
11 Guide pins, 30 Nm
12 Cap
• Remove
13 Bolt
14 Bracket
15 Bolt, ribbed, 190 Nm
• Clean if reusing.
16 Wheel bearing housing
• With bolted brake carrier.
17 Wheel speed sensor
• Before installing sensor, clean the inner surface of the bore and coat with hot bolt paste (G 052 112 A3).
18 Bolt, 8 Nm
19 Wheel bearing/hub unit
• The ABS sensor ring is installed in the wheel bearing.
20 Cover plate