3.1a CII-41 rear brake parts (FWD and AWD models)
1 ABS sensor (FVVD models), before installation, clean the walls of the mounting hole and apply grease G052 112AZ to them
2 Sensor bolt 1 or 8.8 Nm
3 Hub assembly bolts 12, to be replaced, 90 Nm, then retighten by 90°
4 Hub assembly holder (FWD models)
5 Brake guard, various options available
6 Hub assembly holder (AWD models)
7 Hub assembly bolts 9, to be replaced, 70 Nm, then retighten by 90°
8 ABS sensor (AWD models), before installation, clean the walls of the mounting hole and apply grease G052 112AZ to them
9 Hub Assembly (AWD models)
10 Hub bolt (AWD models), to be replaced, 70 Nm, then tighten 90°
11 Shield bolts 5, 12 Nm
12 Hub assembly (FWD models)
13 Brake disc, replace on both sides at the same time
14 Disc bolt 13.4 Nm
15 Hub bolt (FWD models), to be replaced, 180 Nm, then tighten 180°
16 Brake pads, change in pairs, on both sides at the same time
17, 18 Anchoring bracket, with guide pins and caps
19 Shoe holders, must be replaced when replacing shoes
20 Caliper
21 Tube retainer 22
22 Brake pipe, 14 Nm
23 Parking brake cable
24 Self-locking bolt, replaceable, 35 Nm
25 Brake hose
3.1b Bosch BIRIII Rear Brake Parts (FWD and AWD models)
1 Hub assembly bolts 10, to be replaced, 70 Nm, then retighten by 90°
2 ABS sensor (FWD models), before installation, clean the walls of the mounting hole and apply grease G052 112AZ to them
3 Sensor bolt 2 or 4, 8 Nm
4 ABS sensor (FWD models)
5 Hub assembly holder (FWD models)
6 Hub assembly (FWD models)
7 Hub bolt (FWD models), to be replaced, 180 Nm, then tighten 180°
8 Guard of the brake mechanism; on FWD // DI/D models - respectively with 3 // 4 fixing holes
9 Shield bolts 8, 12 Nm
10 Hub assembly (AWD models)
11 Hub bolt (AWD models), to be replaced, 70 Nm, then tighten 90°
12 Brake disc, replaceable on both sides at the same time
13 Disc bolt 12.4 Nm
14 Brake pads, change in pairs, on both sides at the same time
15 Anchoring bracket, with guide pins and caps
16 Shoe holders, must be replaced when replacing shoes
17 Caliper
18 Self-locking bolts, replaceable, 35 Nm
19 Parking brake cable
20 Hose clamp 21
21 Brake hose, with union nut and hollow bolt, 35 Nm
22 Hub assembly holder (FWD models)
23 Clamp bolts 15, to be replaced, 90 Nm, then retighten by 90°
Pad replacement
Note: Replace the brake pads in pairs and on both wheels of the same axle at the same time.
Note: If the pads are not removed for the purpose of replacing them, i.e. will be reinstalled, mark them before removing them so that they can be reinstalled in their original places.
2. Jack up the car and put it on stands. Remove the rear wheel.
3. Remove the caliper mounting bolts while holding the guide pins with an open end wrench (see resist. illustration). Remove the caliper from the anchor bracket without disconnecting the brake hose from it, and fix the caliper on the wire, avoiding tension on the hose.
3.3 Removing the caliper mounting bolts (on the example of CII-41)
4. Remove the brake pads and their retaining plates (see resist. illustration).
3.4 Shoe retaining plates (on the example of CII-41)
5. Before installing the pads, press the piston into the brake wheel cylinder using a suitable tool (see resist. illustration). Do not damage the piston boot. At the same time, make sure that the brake fluid does not spill out of the reservoir, pump it out if necessary.
3.5 Piston indentation
6. Thoroughly clean the caliper and pad mating surfaces. If there is a protective coating on the new pads, remove it. Use only methylated spirits for cleaning, do not blow brake pad dust with compressed air.
7. Install the pads with retaining plates in the caliper. If new pads are installed, use new retaining plates. Make sure that the pads are in the correct position in the retaining plates.
8. Install the caliper and secure it to the anchor bracket by tightening the new self-locking bolts to 35 Nm. At the same time, keep the guide pins from turning.
Note: New self-locking bolts (4 things.) included in the repair kit.
9. Install the wheels and, with the vehicle stationary, depress the brake pedal strongly several times so that the pads assume the working position.
10. Correct the brake fluid level.
Removal and installation, caliper repair
11. Jack up the car and put it on stands. Remove the rear wheel.
12. Disconnect the parking brake cable from the lever on the caliper, then remove the spring clip and pull the cable out of the holder on the caliper.
13. Connect a hose to the bleed valve on the caliper, lower the other end of this hose into a container to collect the brake fluid. Open the bleed valve, depress the brake pedal using VAG1869/2 (or ask an assistant), close the bleed valve and disconnect the hose.
14. Disconnect the caliper brake line.
15. Remove the caliper mounting bolts while holding the guide pins with an open end wrench (see illustration 3.3).
16. Remove the support from the anchor bracket. Caliper repair if needed (piston replacement) be guided by the illustrations.
3.16a Parts of the rear brake caliper CII-41
1 Caliper, with parking brake lever; if the lever is not sealed, replace the caliper and pre-bleed it before installation
2 Cap
3 Bleeding nipple, 10 Nm, lightly lubricate the thread with sealant G052 150A2 before installation
4 Self-locking bolt, replaceable, 35 Nm
5 Guide pin, lubricate before installing
6 Boot, pulled on the bracket 7 and pin 5
7 Anchor bracket with guide pins and their anthers
8 Anchoring bracket with guide pins and their anthers, installed with the load down
9 Boot, pulled by the outer sealing sponge on the piston
10 Piston with automatic adjustment, apply a thin layer of grease G052 150A2 before installation
11 Cuff
3.16b Bosch BIRIII rear brake caliper parts
1-7 see captions to illustration 3.16a
8 Boot, pulled by an outer sealing sponge on the piston
9 Piston with automatic regulator, apply a thin layer of grease G052 150A2 before installation
10 Cuff
17. Follow the steps described in paragraphs 5-7.
18. Connect the caliper brake line and bleed the brake hydraulic drive.
19. Connect and adjust the parking brake cable (see Section 4).
20. Follow the steps described in paragraphs 9-10.