Repairing front brakes, FNR brake caliper as of model year 2001 — VW

Repairing front brakes, FNR brake caliper as of model year 2001
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.
After work for which the brake system had to be opened, bleed the brake system with
brake charge and bleed system
VAS 5234
or extraction unit
V.A.G 1869/4
.
Before removing a brake caliper or disconnecting a brake hose, fit
brake pedal actuator
V.A.G 1869/2
(release pressure in system).
Hexagon bolt, 270 Nm
M18 x 1.5 x 48
Drive shaft
With rotor for speed sensor
Wheel bearing housing
Hexagon bolt, 10 Nm
ABS speed sensor
Before inserting sensor, clean fitting hole inner surface and coat with lubricating paste G 000 650
Allen head bolt, 10 Nm
Cover plate
Brake disc
Brake disc thickness: 26 mm.
Wear limit: 22 mm.
Internally ventilated brake disc: ∅ 313 mm.
When worn, always renew on both sides of axle.
Never remove brake discs from hub by force. If necessary use penetrating fluid, because otherwise brake discs can be damaged.
Hexagon bolt
Allen bolt, 10 Nm
Brake carrier
Supplied as replacement part, assembled with sufficient grease on guide pins.
If protective caps are damaged, use repair kit
Use grease sachet supplied to lubricate guide pins.
Retaining spring
Brake caliper
Do not disconnect brake hose when changing brake pads.
Removing:
Remove brake pads
Chapter
.
Insert
brake pedal actuator
V.A.G 1869/2
(and relieve pressure).
Unscrew brake hose
Item
from brake caliper
Installing:
Installing brake pads
Chapter
.
Connect brake hose
Item
to brake caliper.
Remove
brake pedal actuator
V.A.G 1869/2
.
Bleed brake system
Chapter
.
Repairing
Chapter
.
Brake pads
Thickness 14 mm not including backplate.
Brake pad with retaining spring is seated on piston
When wear reaches a predetermined limit (approx 4 mm) the warning lamp in dash panel insert comes on.
Brake pad with adhesive film on backplate is seated on outer side
Wear limit: 2 mm not including backplate.
Checking thickness
Maintenance
Booklet
10.1
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
.
Guide pin, 30 Nm
Cover cap
Cable bracket
Hexagon bolt, 10 Nm
Brake line, 14 Nm
With retaining spring.
Bracket
Hexagon bolt, 10 Nm
Brake hose