Brake Caliper, Rear Brakes CI 38: Installing

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, 2013 Volkswagen Beetle, and 2012 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Install in reverse order of removal. Note the following:

NOTE:

Replace the self-locking screws for installing the brake caliper.

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

Piston is pressed back. Refer to PRESS THE PISTON BACK .
Brake pads sit on the brake carrier.

Fig 1: Locating Brake Pads On Brake Carrier
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-- check the protective caps for damage and correct seating. Refer to -item 9- OVERVIEW - REAR BRAKE CALIPER, CI 38 REAR BRAKES .

-- Check the guide pins for ease of movement. Refer to -item 8- OVERVIEW - REAR BRAKE CALIPER, CI 38 REAR BRAKES .

-- Attach the brake caliper -1- with the new self-locking screws -arrows- to the brake carrier -2-.

Fig 2: Identifying Brake Caliper & Brake Carrier

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-- Use new self-locking bolts -arrows-.

-- Tighten the brake caliper -1- to the brake carrier -2-.

Fig 3: Removing Brake Caliper From Brake Carrier

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-- While tightening counterhold the guide pin with a suitable wrench -3-.

-- Install the brake line -1- and the brake hose -3- and secure with the clamp -1-.

Fig 4: Identifying Brake Line, Clamp, And Brake Hose

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

-- Push the brake cable -1- through the bracket -4- on the brake caliper until the tabs -3- engage.

Fig 5: Identifying Brake Cable, Lever, Retainers And Brake Caliper Bracket

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-- Push the lever on the brake caliper -2- in direction of -arrow-.

-- Attach the brake cable -1- to the lever -2- on the brake caliper.

-- Bleed the brake system. Refer to DESCRIPTION AND OPERATION .

-- Adjust parking brake. Refer to ADJUSTING .