volkswagen Workshop Repair Guides

Volkswagen Workshop Service and Repair Manuals

ABOUT US
Removing and installing brake pads/linings > < Installing

Golf Mk5

Repairing front brakes, FN 3 brake caliper
Repairing front brakes, FN 3 brake caliper
  Note
t  Every time after changing pads, depress brake pedal firmly several times with vehicle stationary, so that brake pads are properly seated in their normal operating position.
t  Use the brake filling and bleeding equipment -VAS 5234- or the extraction unit -V.A.G 1869/4- to draw off brake fluid from the brake fluid reservoir.
t  Before removing a brake caliper or disconnecting a brake hose, fit brake pedal depressor -V.A.G 1869/2- (when doing this, release pressure in system).
Assembly overview, FN3, 15 inch:
   
1 - Cross head screw / Torx screw, 4 Nm
2 - Brake disc
q   Ventilated, Ø 288 mm
q   Thickness: 25 mm
q   Wear limit: 22 mm.
q   Always renew on both sides of an axle.
q   Remove brake caliper and brake carrier prior to removing.
3 - Brake pads
q   Thickness: 14 mm not including backplate.
q   With break pad wear indicator.
q   When wear reaches a predetermined limit (approx. 4 mm) the warning lamp in the dash panel insert comes on.
q   Wear limit: 2 mm not including backplate.
q   Check thickness → Booklet18.1.
q   Always renew on both sides of an axle.
q   Removing and installing → Chapter.
4 - Retaining spring
q   Insert into both holes in brake caliper.
5 - Brake carrier
q   Bolt to wheel bearing housing.
6 - Brake caliper
q   Do not disconnect brake hose when changing pads.
q   Removing and installing → Chapter.
q   Repairing → Chapter
7 - Guide pin, 30 Nm
8 - Cover cap
q   Remove
9 - Brake hose with banjo union and banjo bolt, 35 Nm
10 - Ribbed bolt, 190 Nm
q   Clean if reused.
11 - Bolt
12 - Bracket
13 - Wheel bearing housing
q   With bolted brake carrier.
14 - ABS speed sensor
q   Before inserting sensor, clean hole inner surface and coat with high-temperature paste G 052 112 A3.
15 - Hexagon socket head bolt, 8 Nm
16 - Splash plate
17 - Hexagon bolt / Torx bolt, 12 Nm
q   M6 x 10 hexagon bolt revised to M6 x 12 Torx bolt
q   Replace hexagon bolt with hexagon bolt and Torx bolt with Torx bolt
18 - Wheel bearing/hub unit
q   ABS sensor ring is installed in wheel bearing.

Assembly overview, FN3, 16 inch:
   
1 - Torx bolt, 12 Nm
2 - Brake disc
q   Ventilated, Ø 312 mm
q   Thickness: 25 mm
q   Wear limit: 22 mm.
q   Always renew on both sides of an axle.
q   Remove brake caliper and brake carrier prior to removing.
3 - Torx bolt, 4 Nm
4 - Brake pads
q   Thickness: 14 mm not including backplate.
q   With break pad wear indicator.
q   When wear reaches a predetermined limit (approx. 4 mm) the warning lamp in the dash panel insert comes on.
q   Wear limit: 2 mm not including backplate.
q   Check thickness → Booklet18.1.
q   Always renew on both sides of an axle.
q   Removing and installing → Chapter.
5 - Retaining spring
q   Insert into both holes in brake caliper.
6 - Brake carrier
q   Bolt to wheel bearing housing.
7 - Brake caliper
q   Do not disconnect brake hose when changing pads.
q   Removing and installing → Chapter.
q   Repairing → Chapter
8 - Guide pin, 30 Nm
9 - Cover cap
q   Remove
10 - Brake hose with banjo union and banjo bolt, 35 Nm
11 - Guide pin, 30 Nm
12 - Cover cap
q   Remove
13 - Bolt
14 - Bracket
15 - Ribbed bolt, 190 Nm
q   Clean if reused.
16 - Wheel bearing housing
q   With bolted brake carrier.
17 - ABS speed sensor
q   Before inserting sensor, clean hole inner surface and coat with high-temperature paste G 052 112 A3.
18 - Hexagon socket head bolt, 8 Nm
19 - Wheel bearing/hub unit
q   ABS sensor ring is installed in wheel bearing.
20 - Splash plate

   

Removing and installing brake pads/linings > < Installing