Repairing rear brakes (disc brakes) — VW

VW
Polo
2002
Running gear
Brake systems
Edition
01.2013
Repairing rear brakes (disc brakes)
Note
After every brake pad change, 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).
1
Cross-head screw, 4 Nm
2
Brake disc
Thickness: 9 mm
Wear limit: 7 mm.
Always renew on both sides of an axle.
Unscrew brake caliper prior to removing.
Never remove brake discs from wheel hub by force. If necessary use penetrating fluid, because otherwise brake discs can be damaged.
3
Cap
Pressing off and driving in
Running gear, axles, steering
Rep. gr.
42
Repairing wheel bearings; Disc brake
.
4
12-point nut (self-locking)
Renew each time after removal
Running gear, axles, steering
Rep. gr.
42
Repairing wheel bearings; Disc brake
.
5
Wheel hub with wheel bearing and rotor
Removing and installing
Running gear, axles, steering
Rep. gr.
42
Repairing wheel bearings; Disc brake
.
6
Hexagon bolt, 30 Nm and turn 90° further
Always renew after removing.
With dished spring
7
Splash plate
8
Stub axle
9
ABS speed sensor
Before inserting sensor, clean inner surface of fitting hole and coat with lubricating paste G 000 650.
10
Hexagon socket head bolt, 8 Nm
11
Axle beam
12
Handbrake cable
Adjusting handbrake
Chapter
.
13
Hexagon socket head bolt, 80 Nm
14
Brake hose
With banjo bolt and seals
Specified torque of banjo bolt to brake caliper
Fig.
Do not disconnect brake hose when changing pads.
15
Self-locking hexagon bolt, 35 Nm
Always renew after removing.
16
Brake caliper
Repairing
Chapter
Removing and installing
Chapter
.
17
Brake pads
Thickness: 11.5 mm
Wear limit: 2 mm not including backplate.
Checking thickness:
Maintenance
Booklet
15.1
.
Always renew on both sides of an axle.
Removing and installing
Chapter
.
18
Pad retainer
Always renew when changing pads.
19
Brake carrier with guide pin(s) 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.
Specified torque of banjo bolt to brake caliper:
Gradual modification of the specified torque from model year 2007:
Brake hose connection piece
arrow
, black chromated
38 Nm
Brake hose connection piece
arrow
, silver-coloured
50 Nm