Repairing front brakes, brake caliper C54 — VW

Repairing front brakes, brake caliper C54
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Torque wrench
V.A.G 1410
Brake pedal depressor
V.A.G 1869/2
Note
After replacing brake pads, depress brake pedal firmly several times with vehicle stationary, so that the brake pads are properly seated in their normal operating position.
Use a bleed bottle which is only used for brake fluid to extract fluid from brake fluid reservoir. Brake fluid is poisonous and must on no account be sucked out by mouth using a hose!
Wheel bolt torque settings
Running gear, axles, steering; Front and four-wheel drive
Rep. Gr.
44
Wheel bolt torque settings
.
Brake hose
Do not disconnect brake hose when changing brake pads.
Spring clip
Brake line, 15 Nm
Screw into brake caliper housing.
Screw into brake hose, counter hold on brake hose hexagon.
Ensure that lugs are properly seated in grooves in bracket.
Self-locking hexagon bolt, 35 Nm
Renew.
When loosening and tightening, counter hold on guide pin.
Self-locking combi-bolt, 120 Nm
Clean ribs if using again.
Brake carrier with guide pin and protective cap
Supplied as replacement part, assembled with sufficient grease on guide pins.
If protective caps or guide pins are damaged, install repair kit. Use grease sachet supplied to lubricate guide pins.
Brake disc
Internally ventilated brake disc: ∅ 280 mm.
Brake disc thickness: 22 mm.
Wear limit: 20 mm.
Always renew both sides.
Remove brake caliper prior to removing.
Never remove brake discs from hub by force. If necessary use penetrating fluid, because otherwise brake discs can be damaged.
Brake pads
Without wear indicator.
Thickness 14 mm not including backplate.
Checking thickness
Maintenance
Booklet
36
Work sequences; Front and rear brake pads/linings: Checking thickness
.
Always renew both sides.
Removing and installing
Chapter
.
Wear limit: 2 mm not including backplate.
Heat shield
Insert into piston.
Brake caliper
Do not disconnect brake hose when changing brake pads.
Removing:
Remove brake pads
Item
Chapter
.
Fit
brake pedal depressor
V.A.G 1869/2
.
Unscrew brake hose
Item
from brake caliper
Installing:
Installing brake pads
Item
Chapter
.
Connect brake hose
Item
to brake caliper.
Remove
brake pedal actuator
V.A.G 1869/2
.
Repairing
Chapter
.
Bracket
Bolt to brake caliper housing.
Hexagon bolt, 10 Nm
Brake pads
With wear indicator.
When wear reaches a predetermined limit (approx 4 mm) the warning lamp in dash panel insert comes on.
Thickness 14 mm not including backplate.
Wear limit: 2 mm not including backplate.
Checking thickness
Maintenance
Booklet
36
Work sequences; Front and rear brake pads/linings: Checking thickness
.
Always renew both sides.
Removing and installing
Chapter
.
Connector
When changing pads, remove from bracket
Item
.
Bracket