Brake Caliper, Replacing : Installing

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Install in reverse order of removal. Note the following:

Tightening specifications. Refer to OVERVIEW - REAR BRAKES .

NOTE: Replace the brake caliper bolts.

-- Clean the brake caliper carrier on the brake pad spring contact surfaces -arrow- and thinly coat them with Lithium grease.

Fig 1: Identifying Brake Pad Spring Contact Surfaces

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-- Install the brake pad springs while paying attention to the installed position.

Fig 2: Identifying Brake Pads Are Located Correctly In Anti-Rattle Springs

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-- Insert brake pads in brake carrier.

NOTE: Make sure the brake pads are seated in the brake pad springs -arrows-.

-- Install the electromechanical parking brake motor. Refer to Installing .

-- Push the brake caliper over the installed brake pads.

NOTE: If the previous brake pads are being reinstalled, the electrical wire for the brake pad wear sensor must be guided through the brake caliper.

-- Tighten the new brake caliper bolts -arrows- by counter-holding the guide pins -1 and 2-.

Fig 3: Identifying Guide Pins

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NOTE:

Make sure that the brake pad wear sensor fits correctly in the brake pad.

Fig 4: Identifying Contact, Dust Cap, Connector

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-- Secure the electrical wire for the brake pad wear sensor with the dust cap -2- as shown.

-- Bring the connector -3- into its installed position and turn in direction of the -arrow- until the tab -4- engages in the hole -5- on the bracket.

-- Connect the connector -6-.

NOTE: Ignore -item 1-.

-- Install the brake hose -1- in the brake caliper and tighten.

Fig 5: Identifying Brake Hose, Union Bolt And Retaining Spring

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-- Check the retaining spring -3- for damage and replace if necessary.

-- Insert the brake hose into the bracket -arrow- and connect it to the brake line by tightening the union bolt -2-.

NOTE:

Make sure the brake hose is routed correctly.

Make sure the brake hose is not blocked, bent or rubbing against the vehicle.

-- Connect the connector -arrow- to the electromechanical parking brake motor.

Fig 6: Identifying Connector

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-- Remove the Brake Pedal Actuator VAG 1869/2.

NOTE: Only bleed the brakes on the wheel which the brake caliper and the brake line was separated. If the brake pedal still feels "soft", completely bleed the brakes. Refer to BRAKE SYSTEM, BLEEDING .

-- Refer to BRAKE SYSTEM, BLEEDING

-- Install the rear wheel. Refer to Wheels, Tires, Wheel Alignment .

-- Depress brake pedal firmly several times with vehicle stationary so that the brake piston reaches its operating position.

-- Drive the parking brake motor out using the Vehicle Diagnostic Tester by following the directions on the display.

WARNING:

Make sure the brakes are working correctly before driving the vehicle for the first time.

After installing, press the brake pedal several times firmly to properly seat brake pads in their normal operating position.

Check brake fluid level, and fill if necessary.