Removing and installing brake caliper, FS III brake caliper

Note

• Use brake filling and bleeding equipment - VAS 5234- to extract brake fluid from brake fluid reservoir.
• Before removing brake caliper or disconnecting brake hose from brake caliper, insert brake pedal actuator - V.A.G 1869/2- to prevent brake fluid reservoir from emptying completely.

Special tools and workshop equipment required

• Torque wrenches - V.A.G 1331-

• Brake pedal depressor - V.A.G 1869/2-

Removing:

• Fit the block for the brake pedal - V.A.G 1869/2- .
• Depress brake pedal at least 60 mm using brake pedal depressor - VAG 1869/2- .
• Remove wheels.

• Disconnect connector -1- for brake pad wear indicator.

Note The plug connection of the brake pad wear indicator is located on the right side of the vehicle.

• Attach bleeder hose -1- of bleeder bottle to bleeder valve of brake calliper
• Open bleed valve.
• Close bleed valve and remove bleed bottle -1-.

• Unscrew threaded connection of brake hose -1- with banjo bolt -2- from brake calliper.
• Immediately seal brake line and threaded hole with sealing plugs - 1H0 698 311 A- .

• Pull cover caps -arrows- out of brake calliper bearing bushes.

• Unscrew both guide pins -arrows- and remove from brake calliper.
• Pull off brake calliper from brake carrier.
• Take brake pads out of brake calliper.

Installation:

Note Before installing, clean carefully and check for wear and damage.

• The piston is removed.
• Insert inner brake pad (piston side) -1- and outer brake pad -2- into brake calliper with retaining springs.
• Inner brake pad (piston side) with large 3-finger clip -1-.
• Outer brake pad with small 3-finger clip -2- (coloured black).

• First, place brake caliper -1- together with brake pads -3- on bottom -arrow A- of the brake carrier -2-.
• Pin -arrow B- of brake calliper -1- must be positioned behind backplate guide -2-!

• Bolt brake calliper -1- with both guide pins -arrows- to backplate and tighten bolts.
• Fit the two protective covers.

• Screw brake hose -1- with banjo bolt -2- on brake calliper.

• Connect brake pad wear indicator connector -1-.

Note The plug connection of the brake pad wear indicator is located on the right side of the vehicle.

• Remove the block for the brake pedal - VAG 1869/2- .
• Bleed brake system.
• Fit the wheels.

Note After changing pads, check the brake fluid level.

Removing and installing brake caliper, FN III brake caliper

Note

• Use brake filling and bleeding equipment - VAS 5234- to extract brake fluid from brake fluid reservoir.
• Before removing brake caliper or disconnecting brake hose from brake caliper, insert brake pedal actuator - V.A.G 1869/2- to prevent brake fluid reservoir from emptying completely.

Special tools and workshop equipment required

• Torque wrenches - V.A.G 1331-

• Brake pedal depressor - V.A.G 1869/2-

Removing:

• Fit the block for the brake pedal - V.A.G 1869/2- .
• Depress brake pedal at least 60 mm using brake pedal depressor - VAG 1869/2- .
• Remove wheels.

• Disconnect connector -1- for brake pad wear indicator.

Note The plug connection of the brake pad wear indicator is located on the right side of the vehicle.

• Attach bleeder hose -1- of bleeder bottle to bleeder valve of brake calliper
• Open bleed valve.
• Close bleed valve and remove bleed bottle -1-.

• Unscrew threaded connection of brake hose -1- with banjo bolt -2- from brake calliper.
• Immediately seal brake line and threaded hole with sealing plugs - 1H0 698 311 A- .

• Unscrew both securing bolts from brake calliper; to do this, counterhold on guide pin.
• Pull the brake caliper from brake carrier.

Installation:

• The piston is removed.
• The two brake pads are seated in the retaining springs on the brake support plate.
• Carefully place the brake calliper on the brake support plate.

• Secure brake calliper to brake support plate with new self-locking bolts, counterholding with the guide bolts.

Installation position of brake hose with banjo union and banjo bolt

You have to make sure that the ring supports of the hoses are resting on the fixing point -arrow-.

• Screw brake hose onto brake caliper.

• Connect brake pad wear indicator connector -1-.

Note The plug connection of the brake pad wear indicator is located on the right side of the vehicle.

• Remove the block for the brake pedal - VAG 1869/2- .
• Bleed brake system .
• Fit the wheels.

Note After changing pads, check the brake fluid level.

Removing and installing brake caliper, Brembo brake caliper

Note

• Use brake filling and bleeding equipment - VAS 5234- to extract brake fluid from brake fluid reservoir.
• Before removing brake caliper or disconnecting brake hose from brake caliper, insert brake pedal actuator - V.A.G 1869/2- to prevent brake fluid reservoir from emptying completely.

Special tools and workshop equipment required

• Torque wrenches - VAG 1332-

• Brake pedal depressor - V.A.G 1869/2-

Removing:

• Fit the block for the brake pedal - V.A.G 1869/2- .
• Depress brake pedal at least 60 mm using brake pedal depressor - VAG 1869/2- .
• Remove wheels.
• Attach the hose of a bleeder bottle onto the to bleeder valve of the brake caliper.
• Open bleed valve.
• Close bleeder valve and remove bleeder bottle.

• Disconnect brake hose -1- from brake caliper.
• Immediately seal brake line and threaded hole with sealing plugs - 1H0 698 311 A- .
• Remove the brake pads.
• Remove bolts -5-. Hold brake caliper in position while doing so.
• Remove the brake calliper.

Installation:

• The piston is removed.
• Install brake caliper.

• Secure brake caliper with new bolts -5-.
• Fit the brake pads .
• Attach brake hose -1- to caliper and tighten connection.

• Remove the block for the brake pedal - VAG 1869/2- .
• Bleed brake system.
• Fit the wheels.

Note After changing pads, check the brake fluid level.