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Volkswagen Workshop Service and Repair Manuals

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Removing and installing brake pads/linings > < Installing

Golf Mk5

Repairing rear brake CII 41
Repairing rear brake CII 41
  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).
I - Assembly overview, front-wheel drive
II - Deviations, four-wheel drive
   
1 - ABS speed sensor
q   Before inserting sensor, clean hole inner surface and coat with high-temperature paste G 052 112 A3.
2 - Hexagon socket head bolt, 8 Nm
3 - Multi-point socket head bolt, 90 Nm and turn 90° further
q   Always renew after removing.
q   Remove and install using socket insert -T10035- → Fig..
4 - Wheel bearing housing
5 - Splash plate
6 - Hexagon bolt, 9 Nm / 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
7 - Wheel bearing/hub unit
8 - Brake disc
q   15 inches: Ø 260 mm; 16 inches: Ø 286 mm; 17 inches: Ø 310 mm
q   Thickness, 15 and 16 inches: 12 mm; 17 inches: 22 mm
q   Wear limit, 15 and 16 inches: 10 mm; 17 inches: 20 mm
q   When worn, renew on both sides of axle.
q   Unscrew brake caliper prior to removing.
9 - Cross-head screw, 4 Nm
10 - Bolt
q   Front-wheel drive only
11 - Brake pads
q   Thickness: 11 mm not including backplate.
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.
12 - Brake carrier with different guide pins and protective cap
q   Supplied as genuine part, assembled with sufficient grease on guide pins.
q   If protective caps or guide pins are damaged, install repair kit. Use lubricant sachet supplied to lubricate guide pins.
q   Installation instructions → Fig.
13 - Pad retainer
q   Always renew when changing pads.
14 - Brake caliper
q   Do not disconnect brake hose when changing pads.
q   Removing and installing → Chapter.
q   Repairing → Chapter
q   Adjust handbrake cable first after repairing or replacement.
q   Adjusting handbrake → Chapter.
15 - Hose retainer
16 - Brake line, 14 Nm
17 - Self-locking hexagon bolt, 35 Nm
q   Renew.
18 - Handbrake cable
q   Adjusting handbrake → Chapter.
19 - Spring clip
20 - Brake hose

   
Installation instructions for brake caliper CII 41, 15 inches, from week 32/2004:
1 - Shorter guide pin with steps -arrows-, leading side
2 - Longer guide pins, phasing out
3 - Balance weight, phasing out
  N46-10095
Tool insert -T10035-
  W00-0946

Removing and installing brake pads/linings > < Installing