Removing
Loosen the wheel bolts, raise the car in front, remove the wheels.
Attention: If the brake linings are to be reinstalled, their location must be marked before removal. It is not allowed to change the pads in places, for example, change the outer one from the inner one or rearrange from the right wheel to the left and vice versa. Changing the location of the pads can lead to uneven braking action. It is recommended to use only original VW/AUDI brake pads. The front brake pads must only be replaced as a set, even if only one pad has reached the wear limit.
Remove the lower caliper housing bolt. In this case, hold the guide pin with a wrench.
Tilt the caliper body up.
Take out the brake pads.
Installation
Attention: When the brake pads are removed, do not depress the brake pedal, otherwise the piston will be pushed out of the caliper housing.
Clean the guide surfaces or pads in the pads with a suitable soft metal brush or wipe with a cloth soaked in alcohol. Do not use solutions containing mineral oils or sharp-edged tools.
Before installing the pads, examine the brake discs to the touch with your fingers for the absence of recesses. Notched discs can be turned (workshop work), depending on whether it has sufficient thickness. Always turn discs on both sides and pay attention to whether sufficient wear reserve remains after turning.
Measure the thickness of the brake discs, see below.
Check dust caps for cracks. Replace damaged caps immediately, as penetrating dirt will quickly break the tightness of the caliper. In this case, the caliper must be removed and disassembled (workshop work).
Check the tightness of the piston heat shield.
Push brake piston -2- back into cylinder using return tool. You can also use a hardwood rod for this (hammer handle), however, pay particular attention to ensure that the piston is not distorted and that the piston surfaces and the dust cap are not damaged.
Attention: When installing the piston in the cylinder, the brake fluid is squeezed out of the brake cylinder into the compensation tank. Monitor the fluid level in the tank and, if necessary, suck out excess fluid with a siphon.
For suction, use a bottle that was used to remove air from the hydraulic system, or a plastic bottle that previously only came into contact with brake fluid. Do not use bottles intended for drinking liquids! Brake fluid is poisonous and must never be sucked out by mouth through a hose. After replacing the brake linings, the level of brake fluid in the compensation tank must also not exceed the mark «MAX», because the liquid expands when heated. The brake fluid flowing out of the reservoir gets under the main brake cylinder, destroys the varnish coating and leads to corrosion.
Attention: If the brake linings are heavily worn, check that the piston can move freely. To do this, insert a wooden block into the caliper and ask an assistant to slowly depress the brake pedal. The piston of the brake cylinder should be easily squeezed out and re-entered. During the check, another caliper must be installed in its place. Make sure that the piston is not completely pressed out. If the piston stroke is heavy, the caliper must be repaired (workshop work).
Insert both brake linings into the brake shield. Make sure that the retaining springs are equally up and parallel to the top edge of the brake linings. Tilt the piston housing from below and screw it to the brake shield with a new self-locking bolt to a torque of 35 Nm. While doing this, hold down the guide pin. Replace damaged guide pin caps (are included in the repair kit).
Attention: A new hex head bolt is included with each original brake pad repair kit for each caliper. These bolts must be used every time.
Screw on the wheel. Lower vehicle and tighten wheel bolts crosswise to 110 Nm.
Caution: Depress the brake pedal strongly repeatedly until strong resistance is felt. In this way, the brake linings are centered and positioned appropriately for the operating conditions.
Check the level of brake fluid in the expansion tank and, if necessary, top up the tank to the mark «MAX».
Carefully run in new brake linings by repeatedly braking the vehicle from a speed of 80 km/h to 40 km/h by lightly depressing the brake pedal. Allow the brakes to cool down between braking.
Attention: On a distance of up to 200 km, braking to a complete stop should not be undertaken.
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