Brake Pads, Removing And Installing: Installing

Install in reverse order of removal and note the following:

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

Brake rotor wear limit. Refer to TECHNICAL DATA, BRAKES .

Always replace brake pads on the same axle at the same time.
Use the complete repair kit when installing new brake pads.

CAUTION:

Health risk due to toxic dust from the brake system.

Irreversible deposit of dust particles in the lungs. Breathing may become impaired.

- Never blow out the brake system with compressed air.

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, 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 .

CAUTION:

There is a risk of contamination and paint damage from leaking brake fluid.

- Check the brake fluid level before pushing the brake caliper piston back into the brake cylinders.

-- If the brake fluid is up to the "MAX" marking on used brake pads, it must be extracted.

Use the : VAS5234 to extract brake fluid from the brake fluid reservoir.

Fig 1: Identifying Piston Pressed Into Brake Caliper Using Piston Resetting Tool

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CAUTION:

Improper handling increases the risk of destroying the brake caliper.

- Never mechanically drive back the pistons.

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

-- Clean the brake carrier on the contact surface -1 and 2- for the brake carrier and coat thinly with Grease.

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

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

-- Insert the brake pads into the brake carrier, while paying attention to the installation position.

Installation Position of the Brake Pads Version 1

Fig 2: Installation Position of the Brake Pads.

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Arrow must point in the wheel direction of rotation
Outer Brake Pad
Inner Brake Pad on Piston Side with Spring -4-

Make sure that the spring sits in the backing plate on the inner brake pad.

Installation Position of the Brake Pads Version 2

Fig 3: Installation Position of the Brake Pads

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A -

Inner Brake Pad on Piston Side

B -

Outer Brake Pad

Make sure that the spring sits in the brake pad backing plate on the inner brake pad.

Continuation for All Brake Types:

-- Coat the guide pins thin with Grease.

-- Insert the brake caliper.

-- Install both guide pins using the : T10503 and : VAS6784 and tighten.

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-- Install the caps -arrows-.

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-- If equipped, connect the brake pad wear sensor connector -2- and secure the wire to the dust protection cap -1-.

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-- Insert the spring -1- for the brake pads in the brake caliper.

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Make sure that the spring is seated completely in the holes -arrow- on the brake caliper.

-- Drive the parking brake motors up using the Vehicle Diagnostic Tester by following the instructions in the display.

CAUTION:

Faulty brakes increase the risk of an accident.

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

-- With the vehicle stationary, firmly press the brake pedal several times so that the brake pads in the operating condition properly sit in their respective position.

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