Order of execution
1. If the condition of the brake pads allows their further use, clean them using a wire brush and a clean rag.
2. Before installing the pads, check that the guide pins move freely in the caliper holder and make sure that the guide pin rubber boots are not damaged.
3. Clean dust and dirt from the caliper and piston.
4. Check the condition of the dust seal around the piston.
5. Using a metal brush, clean the brake disc from any traces of rust.
6. Measure the brake disc thickness.
7. When installing new brake pads, the piston must be screwed into the caliper.
Warning: When the piston is screwed in, the brake fluid is forced out of the brake cylinder into the expansion tank, so keep an eye on the level of the brake fluid in the tank. If necessary pump out a liquid from a tank.
8. To screw the piston into the cylinder, use the VW 3272 tool. To screw in the piston, install the tool so that the tool collar is installed in the grooves of the piston (A - a place to install a wrench).
9. Rotate the body of the special tool counterclockwise until it stops. Rotate the handle of the special tool clockwise to screw the piston into the caliper.
10. If it is difficult to screw in the piston, install a 13 wrench on the slots in the base of the handle and screw the piston by the wrench.
11. If you don't have a special tool, screw the piston into the caliper using angle ring pliers.
12. Install new spring clips into the caliper.
13. Install the brake pads in the caliper holder.
14. If old brake pads are installed, check that they are installed in their original position.
15. When installing new brake pads, remove the protective film from them.
16. Install the caliper and secure it with new bolts, tightening them to 35 Nm.
17. Connect the handbrake cable to the caliper (3), to press the lever (2) in the direction of the arrow and connect the handbrake cable to the lever. Secure the handbrake cable sheath with a spring clip (1).
18. Adjust the hand brake.
19. Install the rear wheels, then lower the vehicle to the ground and tighten the wheel bolts.
20. Press the brake pedal several times to press the brake pads against the brake disc.
21. Check the brake fluid level in the reservoir and top up if necessary.
Warning: Carefully allow new brake pads to run in. To do this, at a speed of about 80 km / h, brake several times to a speed of 40 km / h by lightly pressing the pedal. Allow the brake pads to cool down a little in between.
Warning: After installing new brake pads, avoid hard braking during the first 200 km of the vehicle.
Security Control Check
1. Check if the brake hoses are securely tightened.
2. Check if the brake hose is fixed in the holder.
3. Check if the bleeder fittings are securely tightened.
4. Check if the brake fluid level is sufficient.
5. Check with the engine running. Within about 10 seconds, press the brake pedal with a force of 20–30 kg / m, while the pedal should not fall through.
6. Check the tightness of all listed connections.
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