Brake Pads, Removing And Installing, Pr 1JL, 1ZD: Installing

WARNING: This page is about a different variant/trim than selected.

NOTE:

Clean bolts before reusing.

Replace damaged bolts.

Always replace self-locking bolts.

Install in reverse order of removal and note the following:

If the brake pads are being replaced with new pads, check the brake rotors for wear and damage.

-- Check the wear specification of the brake rotors. Refer to TECHNICAL DATA .

NOTE:

Always replace brake pads on the same axle at the same time.

Use the complete repair kit when installing new brake pads.

WARNING:

Health Risk.

Do not blow out brake system with compressed air.

NOTE:

Use only mineral spirits to clean the brake caliper.

Check the protective caps of the brake caliper pistons for damage and install the complete repair kit, if necessary. Refer to BRAKE CALIPER PISTON/PROTECTIVE CAP/GASKET, REMOVING AND INSTALLING .

Check the bearing bushings of the guide pins for damage and check that the guide pins move easily. Install the complete repair kit, if necessary. Refer to BEARING BUSHING AND GUIDE PIN, REPLACING .

Fig 1: Identifying Brake Charger/Bleeder Unit VAS5234

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CAUTION:

Danger of contamination and paint damage from escaping brake fluid.

If the brake pads are worn out and unnecessary brake fluid was filled, the brake fluid may overflow, when the brake caliper pistons in the brake cylinders are pressed back.
Check the brake fluid level before pressing back the brake caliper pistons. If there is brake fluid up to the "MAX" mark, some brake fluid will need to be extracted.
Use the :VAS5234 to extract brake fluid from brake fluid reservoir.

-- Use the :T10145 to press the brake caliper piston completely back into the brake caliper.

Fig 2: Pressing Piston Back

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-- Clean the brake carrier -1- at the contact surfaces -2- for the brake pads and thinly coat with Lithium Grease :G 052 150 A2 .

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-- If equipped, remove the protective film from the backing plate of the brake pad.

NOTE:

Coat the brake pad plates with grease.

Coat the guide pin with lithium grease.

-- If reusing, install the marked brake pads in the same location.

-- Install the brake pads while paying attention to the installed position. Refer to Figure.

-- Place the brake pads -1- with the springs -2- into the brake carrier opening -3-.

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NOTE:

After installing the brake pads, ensure the proper seating of all springs -2-.

Coat the brake pad plates with grease.

Coat the guide pin with lithium grease.

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

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NOTE:

Clean bolts before reusing.

Replace damaged bolts.

Always replace self-locking bolts.

-- Tighten the brake caliper bolts -arrows- by counterholding at the guide pins -1 and 2-.

NOTE:

Make sure the brake hose is routed correctly.

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

WARNING:

Do not damage the brake hose and brake line.
Do not bend the brake line past the specified form.
A damaged brake hose or a damaged or bent brake line must be replaced.

-- Connect the connector -arrow- for the brake pad wear sensor contact on the right brake caliper.

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WARNING:

Risk of accident!

With the vehicle stationary, firmly press the brake pedal several times so that the brake pads in the operating condition properly seat in their respective position.
Make sure the brakes are working correctly before driving the vehicle for the first time.

-- Check brake fluid level, and fill if necessary.