CII 41 Caliper Overview

CII 41 Caliper Overview

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

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

• Before removing brake caliper or disconnecting brake hose, brake pedal depressor (V.A.G 1869/2) must be inserted (this dissipates pressure).

Special tools, testers and auxiliary items required

• Multipoint Socket (T10035)

I - Front Wheel Drive Assembly Overview

II - All Wheel Drive Differences






1 ABS Wheel Speed Sensor

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

2 Hex Socket Head Bolt

• 8 Nm

3 Internal Multi-Point Bolt

• 90 Nm + 90°

• Always replace if removed.

• Removing and installing with (T10035).

4 Wheel Bearing Housing

5 Cover Plate

6 Hex Head Bolt, 9 Nm/TORX(R) Bolt

• 12 Nm

• Hex head bolt M6x10 changed from TORX(R) bolt M6x12.

• Replace hex head bolt with hex head bolt and TORX(R) bolt with TORX(R) bolt.

7 Wheel Bearing/Hub Unit

8 Brake Rotor

• Diameter 15 inch: 260 mm, 16 inch: diameter 286 mm, 17 inch: diameter 310 mm

• 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 Screw

• 4 Nm

10 Bolt

• Only on front wheel drive.

11 Brake Pads

• Thickness 11 mm without backing plate

• Wear limit: 2 mm without backing plate

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

• Removing and Installing, refer to => [ Brake Pads, CII 41 ] Brake Pads, CII 41.

12 Brake Carrier with Different Guide Pins and Protective Cap

• Supplied as an 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: => [ Assembly Guide, Brake Carrier CII 41 15 inch from CW 32/04: ].

13 Brake Pad Retaining Plate

• Always replace when pads are replaced.

14 Brake Caliper

• Do not remove the brake hose when changing the brake pads.

• Removing and Installing, refer to => [ Brake Caliper, CII 41 ] Brake Caliper, CII 41.

• Servicing, refer to => [ Rear Brake Caliper, Servicing ] Procedures.

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

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

15 Hose Retainer

16 Brake Line

• 14 Nm

17 Self-Locking Bolt

• 35 Nm

• Replace

18 Parking Brake Cable

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

19 Spring Clamp

20 Brake Hose

Assembly Guide, Brake Carrier CII 41 15 inch from CW 32/04:





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

2. Longer guide pins, outgoing.

3. Vibration dampener, outgoing.