NOTE: To drain the brake fluid from the reservoir, use the MS 5234 brake system filling and bleeder or the VAG 1869/4 brake system filling and bleeder. Before dismantling the brake caliper or disconnecting the brake hose, install the brake pedal stop VAG 1869/2 (at the same time reduce the pressure).
Removing the brake pads
Mark the brake pads if they are to be reused. They must be installed back in their places, otherwise there will be an uneven distribution of braking forces between the wheels.
Remove wheels.
Disconnect the plug connection 1 of the brake pad wear indicator (pic. 6.36).
Remove cap 2 and remove brake pad wear indicator cable.
Remove the bolt (pic. 6.37).
Press the retaining spring down and at the same time remove the brace 1 (pic. 6.38).
Remove the brake pad wear indicator cable from the brake caliper housing and retaining spring 1 (pic. 6.39).
Remove retaining spring (pic. 6.40).
Before wringing out the brake pads, it is necessary to pump out the brake fluid from the reservoir. If the brake fluid is topped up as the brake pads wear, this will help to avoid fluid leaks and the resulting damage.
Press the brake pads off the brake disc and remove from the brake caliper.
Replace brake pads if necessary. Carefully remove the contact sensor with the brake pad wear indicator cable from the brake pads and check for damage.
An undamaged contact probe and cables can be used later.
Clean the caliper.
Use only alcohol to clean the brake caliper.
Installation of brake pads
Before pressing the pistons into the cylinder using a special device, it is necessary to pump out the brake fluid from the reservoir. If the brake fluid is topped up as the brake pads wear, this will help to avoid fluid leaks and the resulting damage. Press out the pistons.
Install the brake pad wear indicator cable contact gauge carefully into the new brake pads.
Install the brake pads into the brake caliper.
Install retaining spring 1 (pic. 6.40).
Install the brake pad wear indicator cable under the retaining spring lug in the brake caliper housing.
Press the retaining spring down and press the brace 1 until it stops (pic. 6.39).
Make sure that the side end surfaces of the brace sit correctly in the brake caliper housing so that they cannot turn.
Tighten the bolt (pic. 6.37).
Connect the plugs 1 of the brake pad wear indicator in the holder on the wheel bearing housing (pic. 6.36).
Attach the brake pad wear indicator cable with cap 2 to the bleed valve.
Install wheels.
NOTE: After each replacement of the brake pads, depress the brake pedal firmly several times. This is necessary in order for the brake pads to take their working position. After replacing the pads, check the brake fluid level.
Torque
Hexagonal bolt for stretching: 30 Nm.
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