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 (V.A.G 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 (V.A.G 1869/2) must be inserted (this dissipates pressure).





1 Wheel speed sensor

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

2 Bolt, 8 Nm

3 Bolt, 90 Nm + 90° additional turn

• Always replace after removal.

4 Wheel bearing housing

5 Cover plate

6 Bolt, 9 Nm

7 Wheel bearing/hub unit

8 Bolt

9 Dust cap


10 Brake disc

• Brake caliper CII 38: 286 mm diameter.

• Brake caliper CII 41 (15"): 260 mm diameter.

• Brake caliper CII 41 (16"): 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.

11 Bolt, 4 Nm

12 Brake pads

• Thickness: 11 mm without backing plate.

• 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.

13 Brake carrier with guide pins and protective cap

• Supplied as a pre-assembled replacement part with sufficient grease on the guide pins.

• If the protective caps or guide pins are damaged, install repair kit. Use supplied grease packet to lubricate the guide pins.

14 Anti-rattle clips

• Always replace when pads are replaced.

15 Brake caliper

• Do not remove brake hose when replacing brake pads.

• Removing and installing, refer to --> [ Brake Caliper ] Brake Caliper.

• Assembly overview, refer to one of the following:

• With a CII 38 rear caliper, refer to --> [ Brake Caliper Assembly Overview ] Brake Caliper Assembly Overview.

• With a CII 41 rear caliper, refer to --> [ Brake Caliper Assembly Overview ] Brake Caliper Assembly Overview.

• After servicing or replacing, parking brake cable must be adjusted.

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

16 Hose retainer

17 Brake line, 14 Nm

18 Bolt, 35 Nm

• Self locking

• Replace

19 Parking brake cable

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

20 Spring clamp

21 Brake hose