Volkswagen Golf Service & Repair Manual: Removing and installing brake caliper

Volkswagen Golf Service & Repair Manual / Brake system / Brake, brake mechanics / Rear brakes / Removing and installing brake caliper

Removing and installing brake caliper

Special tools and workshop equipment required

Vehicle diagnosis, testing and information system -VAS 5051-

Tool set for brake bleeding -VAS 6564-

Insert tool with ratchet -VAS 6784-

Bit attachment (7 mm) -T10503-

Torque wrench -V.A.G 1331-

Piston resetting appliance -T10145-

Brake pedal depressor -V.A.G 1869/2-

Removing

Note

This procedure applies only to exchanging or the following repair work on the brake caliper.

Note

Do not separate connectors of parking brake motors.

–	Remove rear wheel on relevant side.

The electromechanical parking brake pistons must be moved back using → Vehicle diagnostic tester.

Note

Before resetting pistons, draw off brake fluid from brake fluid reservoir. Otherwise, particularly if reservoir has been topped up, fluid will overflow and cause damage.

–	Move back pistons using → Vehicle diagnostic tester.

Removing and installing brake caliper

–	Unscrew bolts -arrows- for parking brake motor.

–	Pull off parking brake motor and place it to one side without disconnecting the connector.

Removing and installing brake caliper

–	Connect bleed bottle bleed hose -1- to bleed valve of brake caliper.

–	Open bleed valve.

–	Apply brake pedal depressor -V.A.G 1869/2-.

–	Close bleed valve and remove bleed bottle.

–	Unscrew brake hose.

Risk of injury due to tensioned retaining spring.The retaining spring might jump out and cause injury to eyes and skin.Make sure to firmly hold the retaining spring.

Removing and installing brake caliper

–	Use a screwdriver -A- to lever retaining spring -1- for brake pads out of brake caliper -arrow- while supporting retaining spring with the other hand.

Removing and installing brake caliper

–	Remove cover caps -arrows-.

Removing and installing brake caliper

–	Unscrew both guide pins from brake caliper using 7 mm bit -T10503- and insert tool with ratchet -VAS 6784-.

–	Pull brake caliper off brake carrier.

Installing

Install in reverse order of removal, observing the following:

The brake pads are seated in the retaining springs on the brake carrier.

–	Secure brake caliper to brake carrier with new self-locking bolts.

Note

The annular groove and the contact surface of the parking brake motor must be clean.

–	Install new sealing ring.

–	Turn spindle back slightly using an E11 Torx socket until parking brake motor can be properly fitted.

–	Carefully fit parking brake motor, while ensuring that seal is correctly seated.

–	Turn parking brake motor until bolt hole and thread align.

Note

Make sure that parking brake motor is flush with brake caliper. Never pull parking brake motor onto brake caliper using securing bolts.

–	Start new hexagon socket head bolts by hand and tighten them.

–	Attach brake hose to brake caliper.

–	Bleed brake system → Chapter.

After moving the pistons forwards using → Vehicle diagnostic tester, carry out a basic setting of brake system.

–	Carry out basic setting of brake system using → Vehicle diagnostic tester.

–	Fit wheel.

Specified torques

→ Chapter „Assembly overview - rear brakes“

Bleed valve → Chapter „Assembly overview - rear brake caliper“

Wheel bolts → Running gear, axles, steering; Rep. gr.44.

Note

Check brake fluid level.

Removing and installing brake caliper

Removing and installing brake pads or linings

Special tools and workshop equipment required Vehicle diagnosis, testing and information system -VAS 5051- Tool set for brake bleeding -VAS 6564- ...

Handbrake

...

Other materials:

Pressures and temperatures in the refrigerant circuit
WARNING When working on the refrigerant circuit, observe generally applicable safety rules and the Regulations for Pressure Tanks. The pressures and temperatures in the ref ...

Assembly overview - towing bracket socket
1 - Trailer detector control unit -J345- Removing and installing → Chapter 2 - Retaining frame For trailer detector control unit -J345- 3 - Trailer socket -U10- ...

Tyre ageing
Even visually flawless, new or barely used tyres with sufficient tread depth, which are older than six years, may show significant reduction of wet properties and winter suitability due only to ageing. Tyre tests show that a contin ...