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Volkswagen Workshop Service and Repair Manuals

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Golf Mk5

Repairing rear brake caliper
Repairing rear brake caliper
t  When carrying out repairs, install all parts supplied in repair kit.
t  Use only methylated spirits for cleaning the brake.
t  New brake calipers are filled with brake fluid and are pre-bled.
t  Apply thin coat of assembly paste G 052 150 A2 to brake cylinder, piston and sealing ring.
t  When repairs are performed, it is essential to appropriately pre-bleed brake calipers (without brake pads) before installing in vehicle → Chapter.
Assembly overview of brake calipers CI 38 and CII 38:
   
1 - Brake caliper with handbrake cable lever
q   If there is a leak at handbrake cable lever, renew brake caliper.
q   Following repair work, pre-bleed brake caliper → Chapter.
2 - Dust cap
3 - Bleeder valve, 10 Nm
q   Apply thin coat of assembly paste G 052 150 A2 to thread before screwing in.
4 - Self-locking hexagon bolt, 35 Nm
q   Renew.
q   When loosening and tightening, counterhold on guide pin.
5 - Guide pin
q   Grease before fitting protective cap.
6 - Protective cap
q   Fit onto brake carrier and guide pin.
7 - Brake carrier with guide pin(s) and protective cap
q   Illustration for CII 38 brake
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.
8 - Protective cap
q   Pull on so that outer sealing lip goes over piston.
q   Removing and installing → Chapter.
9 - Piston with automatic adjustment
q   Removing and installing → Chapter.
q   Apply thin coat of assembly paste G 052 150 A2 to piston before installing.
10 - Sealing ring
q   Removing and installing → Chapter.

Assembly overview of brake caliper CII 41:
15 inches from week 32/2004:
   
1 - Brake caliper with handbrake cable lever
q   If there is a leak at handbrake cable lever, renew brake caliper.
q   Following repair work, pre-bleed brake caliper → Chapter.
2 - Dust cap
3 - Bleeder valve, 10 Nm
q   Apply thin coat of assembly paste G 052 150 A2 to thread before screwing in.
4 - Self-locking hexagon bolt, 35 Nm
q   Renew.
q   When loosening and tightening, counterhold on guide pin.
5 - Guide pins with steps
q   Shorter than item 6
q   Grease before fitting protective cap.
6 - Guide pin
q   Longer than item 5
q   Grease before fitting protective cap.
7 - Protective cap
q   Fit onto brake carrier and guide pin.
8 - Brake carrier with balance weight
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.
9 - Protective cap
q   Pull on so that outer sealing lip goes over piston.
q   Removing and installing → Chapter.
10 - Piston with automatic adjustment
q   Removing and installing → Chapter.
q   Apply thin coat of assembly paste G 052 150 A2 to piston before installing.
11 - Sealing ring
q   Removing and installing → Chapter.

   

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