Brake pads, removing and installing

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Fig 1: Identifying Special Tools - Brake Pads, Removing And Installing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Special tools, testers and auxiliary items required

Torque wrench V.A.G 1331
Torque wrench V.A.G 1410
Brake pedal actuator V.A.G 1869/2
Piston resetting tool T10145

Torque wrench V.A.G 1332

Removing

Raise vehicle.
Remove wheels.

NOTE:

If reusing brake pads, mark location. Install in same position when installing otherwise uneven braking will occur!
The brake disc is secured with a Torx bolt.

Fig 2: Caliper Guide Pin Caps

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Remove protective caps - arrows -.

Fig 3: Brake Wear Pad Indicator Connector

Courtesy of VOLKSWAGEN UNITED STATES, INC.

On vehicles equipped with a brake pad wear indicator disconnect connector - 1 -.
Slightly lift up locating lug on lower part of connector - 2 - and turn 90°.
Pull lower part of connector out of holder.

Fig 4: Removing Brake Pad Retaining Spring From Brake Caliper Housing

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Use a screwdriver to pry off brake pad retaining spring from brake caliper housing and remove.

Fig 5: Removing/Installing Caliper Guide Pins

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Unscrew and 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 from brake caliper housing and/or brake carrier.

Installing

Fig 6: Pressing Piston Back Into Caliper Housing

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Press piston back into caliper housing.

Use methylated spirits to clean brake caliper housing.

NOTE:

Before inserting new brake pads, press the piston back into the cylinder using the piston resetting tool. Before pressing the piston back, draw off brake fluid from the reservoir with a bleeder bottle. Otherwise fluid will overflow and cause damage if the reservoir was topped off during repair work.

CAUTION: Brake fluid is poisonous and must never be extracted by mouth using a hose!

Fig 7: Inserting Brake Pad With Retaining Spring Into Brake Caliper Housing (Piston)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Insert brake pad with retaining spring into brake caliper housing (piston).

NOTE:

The inner surface (with tension spring) is indicated by an arrow. The arrow must point in the rotation direction of the brake rotor when driving forward. If improperly installed, noises could result.

Fig 8: Inserting Brake Pad With Retaining Spring Into Brake Caliper Housing (Piston)

Courtesy of VOLKSWAGEN UNITED STATES, INC.

Pull off protective foil on backing plate of outer brake pad.
Install outer brake pad onto brake carrier.
Secure brake caliper housing to brake carrier with both guide pins (tighten to 25 Nm).
Install both protective caps.

Insert retaining spring into brake caliper housing.
Connect electrical connector for brake pad wear indicator.

Mount wheels → 44 - WHEELS, TIRES, VEHICLE ALIGNMENT .

NOTE:

The retaining spring must be pressed under the brake carrier after inserting into both holes. If incorrectly installed, the wear of the outer pad cannot be adjusted, and the pedal travel will be increased as a result.
After installing the brake pads, depress pedal firmly several times with the vehicle stationary, so that the brake pads are properly seated in their normal operating position.

Check brake fluid level and top off if necessary.