Volkswagen Workshop Service and Repair Manuals

Removing and installing brake calipers, Bosch Special tools and workshop equipment required

t  Torque wrench -V.A.G 1331-

t  Brake pedal depressor -V.A.G 1869/2- Removing This procedure applies only to exchanging or the following repair work on the brake caliper. –  Raise vehicle. –  Remove rear wheels.

–  Press level on brake caliper -2- in -direction of arrow-. –  Unhook handbrake cable -1- from lever on brake caliper -2-. –  Press locking lugs -3- together and remove handbrake cable -1- from bracket -4- on brake caliper.

–  Connect bleed bottle bleed hose -1- to brake caliper bleed valve and open bleed valve.

–  Apply brake pedal depressor -V.A.G 1869/2-. –  Close bleed valve and remove bleed bottle.

–  Release brake hose -1- connection with banjo bolt -2- on brake caliper.

–  Unscrew bolts -arrows- from brake caliper -1-; to do this counterhold on guide pin. –  Remove brake caliper from brake carrier. Installing Install in reverse order. Note the following points: l  Piston is pressed back. l  The brake pads are seated in the retaining springs on the brake carrier. –  Secure brake caliper to brake carrier with new self-locking bolts.

–  Screw brake hose -1- with banjo bolt -2- on brake caliper. –  Remove brake pedal depressor -V.A.G 1869/2-.

–  Guide handbrake cable -1- through bracket -4- on brake caliper until locking lugs -3- engage. –  Press level on brake caliper -2- in -direction of arrow-. –  Attach handbrake cable -1- to lever -2- on brake caliper. –  Bleed brake system → Chapter. –  Adjust handbrake → Chapter. –  Fit wheels. Specified torque of wheel bolts → Running gear, axles, steering; Rep. gr.44.   Note t  Firmly depress brake pedal several times with vehicle stationary so that the brake pads are properly seated in their normal operating position. t  Check brake fluid level.

Component	Specified torque
Brake caliper to brake carrier t  Use new bolts.	35 Nm
Brake hose with banjo bolt to brake caliper	35 Nm