Front brakes, servicing

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Fig 1: Identifying Special Tools - Front Brakes, Brembo 18

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

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!

CAUTION: If brake pads are ceramics, wheel must not fall on brake disc, otherwise it will be irreparably damaged. To remove/install wheel, insert two assembly pins in wheel bolt mount.

Fig 2: Exploded View Of Front Brakes, Brembo 18

Courtesy of VOLKSWAGEN UNITED STATES, INC.

1 - Brake disc

Ventilated brake disc: 365 mm diameter
Brake disc thickness: 34 mm
Wear limit: 32 mm
Always replace both sides

Remove brake caliper prior to removing

2 - Brake caliper

Do not disconnect brake line when changing brake discs
Removing:
Insert brake pedal actuator V.A.G 1869/2
Removing and installing → Brake pads, removing and installing

Installing:
Remove brake pedal actuator V.A.G 1869/2
Bleed braking system → Brake system, bleeding

3 - Ribbed bolt, 200 Nm

If re-using, clean ribs

4 - Bracket

Bolt to brake caliper housing

5 - Hex head bolt, 25 Nm

6 - Brake line, 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 grooves in bracket.

7 - Spring clip

8 - Brake hose

Do not disconnect brake line when changing brake discs

9 - Hex socket head bolt, 110 Nm

Replace each time

10 - Torx screw

Torque specification 5 Nm

11 - Retaining springs

12 - Brake pad retaining pins

13 - Brake pads

With wear indicator
Thickness 11.4 mm without backing plate
Wear limit: 7 mm including backing plate
When wear limit is reached (limit: 2 to 3 mm), a warning light comes on in instrument cluster

Checking thickness 803Work sequences; Front and rear brake pads/linings; Checking thickness
Always replace both sides
Removing and installing → Brake pads, removing and installing