Front brakes, servicing

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NOTE:

Install complete repair kit.
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 extract brake fluid from the brake fluid reservoir, use a bleeder bottle that only comes into contact with brake fluid. Brake fluid is poisonous and must never be extracted by mouth using a hose!
Check brake caliper for ease of movement by moving it sideways.

Fig 1: Exploded View Of Front Brakes FNR-G60

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Brake pads

NOTE:

The inner surface (with tension spring) is equipped with a cable for wear indicator.
Always replace both sides
Before installing the brake pads, clean guide surfaces and apply a thin coating of polycarbamide grease G 052 142 A2 .
Removing and installing → Brake pads, removing and installing
Checking pad thickness:
Different versions ETKA

NOTE:

Always clean the brake caliper thoroughly (grease-free) before inserting new brake pads. It is important to make sure that contact surfaces for brake pads are clean.

2 - Brake carrier

Bolt to wheel bearing housing

3 - Ribbed bolt, 190 Nm

Clean ribs if using again
M14x1.5x 38

4 - Bearing bushing

Insert into brake caliper housing

5 - Guide pins, 30 Nm

6 - Protective cap

Remove
Insert wear indicator wire in protective cap

7 - Brake disc

Always replace both sides
Remove brake caliper prior to removing
Lubricate contact surfaces between brake disc and wheel hub with polycarbamide grease G 052 142 A2 . → 44 - WHEELS, TIRES, VEHICLE ALIGNMENT
Thickness → Brakes

Application → Brakes

8 - Wheel bolts

Mounting wheels → 44 - WHEELS, TIRES, VEHICLE ALIGNMENT

9 - Torx bolt

Tightening torque: 5 Nm

10 - Spring clip

11 - Brake line connection to brake hose, 15 Nm

12 - Brake line

Screw into brake caliper housing
Screw into brake hose, counter hold on brake hose hex.
Do not twist hose when installing
Make sure that lugs are properly seated in grooves in bracket.

13 - Brake line connection to brake caliper, 17 Nm

14 - Bracket

Bolt to brake caliper housing
Attach brake line

15 - Hex bolt M 8 x 16

Tightening torque: 25 Nm

16 - Brake caliper housing

If assembly work is required, do not leave caliper hanging from brake hose but secure it to body with binding wire
With exception of "replacing brake pads" → Brake pads, removing and installing and "Servicing front brake caliper" , no repairs may be performed on the brake caliper.
Do not twist hose when installing

17 - Retaining spring

Note correct installation position.

NOTE:

After inserting the retaining spring into the two holes, press it under the brake carrier. If incorrectly installed, it is not possible to adjust the wear of the outer pad, and the pedal travel will be increased as a result.