Repairing rear brake CII 41 — VW

Repairing rear brake CII 41
Note
Every time after changing pads, depress brake pedal firmly several times with vehicle stationary, so that brake pads are properly seated in their normal operating position.
Use the
brake filling and bleeding equipment
VAS 5234
or the extraction unit
V.A.G 1869/4
to draw off brake fluid from the brake fluid reservoir.
Before removing a brake caliper or disconnecting a brake hose, fit
brake pedal depressor
V.A.G 1869/2
(when doing this, release pressure in system).
I - Assembly overview, front-wheel drive
II - Deviations, four-wheel drive
ABS speed sensor
Before inserting sensor, clean hole inner surface and coat with high-temperature paste G 052 112 A3.
Hexagon socket head bolt, 8 Nm
Multi-point socket head bolt, 90 Nm and turn 90° further
Always renew after removing.
Remove and install using
socket insert
T10035
Fig.
.
Wheel bearing housing
Splash plate
Hexagon bolt, 9 Nm / Torx bolt, 12 Nm
M6 x 10 hexagon bolt revised to M6 x 12 Torx bolt
Replace hexagon bolt with hexagon bolt and Torx bolt with Torx bolt
Wheel bearing/hub unit
Brake disc
15 inches: ∅ 260 mm; 16 inches: ∅ 286 mm; 17 inches: ∅ 310 mm
Thickness, 15 and 16 inches: 12 mm; 17 inches: 22 mm
Wear limit, 15 and 16 inches: 10 mm; 17 inches: 20 mm
When worn, renew on both sides of axle.
Unscrew brake caliper prior to removing.
Cross-head screw, 4 Nm
Bolt
Front-wheel drive only
Brake pads
Thickness: 11 mm not including backplate.
Wear limit: 2 mm not including backplate.
Check thickness
Maintenance
Booklet
18.1
.
Always renew on both sides of an axle.
Removing and installing
Chapter
.
Brake carrier with different guide pins and protective cap
Supplied as genuine part, assembled with sufficient grease on guide pins.
If protective caps or guide pins are damaged, install repair kit. Use lubricant sachet supplied to lubricate guide pins.
Installation instructions
Fig.
Pad retainer
Always renew when changing pads.
Brake caliper
Do not disconnect brake hose when changing pads.
Removing and installing
Chapter
.
Repairing
Chapter
Adjust handbrake cable first after repairing or replacement.
Adjusting handbrake
Chapter
.
Hose retainer
Brake line, 14 Nm
Self-locking hexagon bolt, 35 Nm
Renew.
Handbrake cable
Adjusting handbrake
Chapter
.
Spring clip
Brake hose
Installation instructions for brake caliper CII 41, 15 inches, from week 32/2004:
Shorter guide pin with steps
arrows
, leading side
Longer guide pins, phasing out
Balance weight, phasing out
Tool insert
T10035