2FN Brake Caliper, Servicing
2FN brake caliper, servicing
Special tools and workshop equipment required
^ VAG 1331 Torque wrench (or equivalent)
^ VAG 1410 Torque wrench (or equivalent)
^ VAG 1 869/2 Brake pedal depressor
Notes:
^ Install repair kit complete.
^ After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position.
^ To draw off brake fluid from the reservoir, use a bleeder bottle, which is used only for brake fluid. Brake fluid is poisonous, NEVER siphon brake fluid by mouth!
^ Wheel bolt tightening torque
1 - Brake hose
^ Do not disconnect brake hose when changing brake pads
2 - Retainer
^ Bolt to brake caliper housing
3 - Spring clip
4 - Brake pipe, 15 Nm
^ Screw into brake caliper housing
^ Screw into brake hose, counter hold on brake hose hex.
^ Make sure that lugs are properly seated in retainer grooves.
5 - Hex bolt, 8 Nm
6 - Protective cap
^ Take off
^ Upper protective cap with cable holder for brake pad wear indicator
7 - Guide pins, 25 Nm
8 - Ribbed combi bolt, 190 Nm
^ Clean ribs if using again
9 - Brake carrier
^ Bolt to wheel bearing housing
10 - Bearing bushing
11 - Brake caliper
^ Do not disconnect brake hose when changing brake pads
^ Removing:
- Remove brake pads
- Install brake pedal depressor VAG 1869/2
- Remove brake hose -item 1 -from brake caliper
^ Installing:
- Install brake pads5
- Install brake hose -item 1 -onto brake caliper
- Remove brake pedal depressor VAG 1869/2
- Bleed brake system
12 - Retaining spring
^ Insert in both brake caliper housing drillings
Note: Inserting info both holes the retaining spring must be pushed under the brake carrier. Faulty installation will not allow compensation of outer pad wear and therefore the pedal travel increases.
13 - Brake pads
^ With wear indicator
^ Thickness 14 mm
^ Wear limit: 7 mm including backing plate
^ With wear indicator
- Warning lamp lights up on instrument panel when wear limit is reached (limit: 2 to 3 mm)
^ Checking thickness
^ Always replace both sides
14 - Brake disc
^ Ventilated brake disc: diameter 334 mm
^ Brake disc thickness: 32 mm
^ Wear limit: 30 mm
^ Always replace both sides
^ Left differs from right. Arrow points in direction of normal travel
^ Remove brake caliper prior to removing
Brake pads, removing and installing
Special tools and workshop equipment required
^ VAG 1331 Torque wrench (or equivalent)
^ Piston resetting tool
Removing
Note: When reusing brake pads mark location, install in same position otherwise uneven braking!
^ Remove wheels.
^ Secure brake disc using a wheel bolt.
^ Push retaining spring in direction of arrow and remove from brake caliper sideways.
^ Separate the connector -1- for brake pad wear indicator.
^ Lift locking tab slightly on connector lower part -2- and then turn 90°.
^ Pull connector lower part out of bracket.
^ Remove protective caps -1-.
Upper protective cover with cable holder for brake pad wear indicator
^ Remove both guide pins from brake caliper.
^ Remove brake caliper housing and lay to one side so that the weight of the brake caliper does not stress or damage the brake hose.
^ Remove brake pads out of brake caliper housing or brake carrier.
Use only appropriate solvent for cleaning the brake caliper housing.
Installing
Note: Before installing new brake pads, press piston back into the cylinder with resetting tool. Draw off brake fluid from the reservoir with a bleeder baffle. Before pressing the piston back, make sure reservoir has not been topped off, otherwise fluid will overflow and cause damage.
^ Press piston back into brake caliper.
^ Insert brake pad with retaining spring in brake caliper housing (piston).
^ Install outer brake pad to brake carrier.
^ Bolt brake caliper housing to brake carrier with both guide pins.
^ Install both protective caps.
The brake wear indicator wiring must be routed beneath the bracket on the brake caliper.
^ Install brake pad wear indicator connector under dust cap of bleed valve, in upper protective cap and in bracket on brake caliper.
^ Install brake wear indicator connector into bracket on brake caliper.
^ Install retaining spring into brake caliper housing and then press under brake carrier.
Note:
^ After brake pad change with vehicle stationary, firmly depress brake pedal several times so that the brake pads are properly seated in their normal operating position.
^ Check brake fluid level, after changing brake pads.