Contents: Removal ↓ Installation ↓
Removal
Loosen the wheel bolts. Raise the car and remove the wheel.
Unscrew the 2 ribbed bolts of the front caliper or, respectively, the 2 hexagonal-head bolts of the rear caliper and remove the caliper complete with the brake shield from the wheel hub bearing housing. See also the overview drawings of the front and rear wheel calipers for the locations of the mounting bolts.
If necessary, detach the brake hose from the wheel bearing housing.
Hang the brake caliper on a hook made from wire so that the brake hose is not twisted or stretched.
Caution: Do not loosen the brake hose, otherwise you will need to bleed air from the brake system.
If the caliper is to be removed completely, the brake hose of the brake actuator coupling head must first be unscrewed. Otherwise, the brake hose cannot be unscrewed from the caliper.
Caution: Brake fluid will leak out. Collect the brake fluid in a bottle that is only intended for brake fluid. Brake fluid can also be sucked out of the expansion tank using a siphon. The handbrake cable must also be removed from the rear caliper.
Front brake disc: Remove the countersunk screw.
Remove the brake disc.
Caution: The brake disc must not be separated from the wheel hub by force (hammer blows). Instead, use a standard rust remover to avoid damaging the disc. If removal is only possible by strong hammer blows, both the brake disc and the wheel bearing must be replaced for safety reasons. The front wheel bearing should only be replaced in a workshop, as this is usually the only place where the appropriate press is available. The brake disc should also be replaced using a suitable puller.
Installation
In order to guarantee uniform braking on both sides, both brake discs must have identical surfaces in terms of wear pattern and unevenness depth. Therefore, both brake discs must be replaced or ground.
The brake discs can be checked for runout in the workshop. The maximum measured runout value of the brake surface should not exceed 0.03 mm. The maximum permissible thickness difference for one disc is 0.01 mm.
Measure the thickness of the disc, see above. If there is rust on the brake disc flange and front wheel hub, remove it with a wire brush.
Clean the new brake discs from the protective varnish with nitro solvent. 9 Put the brake disc on the wheel hub. Tighten the front brake discs with a countersunk head screw. Insert the caliper with the installed brake pads. The brake hose should not twist or stretch. Check the freedom of movement of the brake hose when turning the steered wheels to the stop. Connect the handbrake cable to the rear caliper.
Attach the brake hose to the wheel bearing housing.
Tighten the front brake caliper to a torque of 125 Nm. If used ribbed head bolts are reused, the ribbed head must first be cleaned with a wire brush.
Tighten the rear brake caliper to a torque of 65 Nm.
Caution: If the brake hose has been removed, tighten the brake hose and bleed the brake system, see below.
Tighten the wheel. Lower the car and tighten the wheel bolts crosswise to 110 Nm.
[The information is available on the website vwmanual.ru]
Caution: Press the brake pedal hard repeatedly until you feel strong resistance.
If the rear brake disc was removed, perform a basic adjustment of the rear wheel brake.
Check the fluid level in the expansion tank, see below.
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