3.1a Rear brake mechanism parts CII-41 (fWD and AWD models)
1 ABS sensor (fVVD models), before installation, clean the walls of the mounting hole and apply G052 112A3 grease to them
2 Sensor bolt 1 or 8, 8 Nm
3 Hub assembly bolts 12, to be replaced, 90 Nm, then tighten to an angle of 90°
4 Hub assembly holder (fWD models)
5 Brake shield, different options available
6 Hub assembly holder (aWD models)
7 Hub assembly bolts 9, to be replaced, 70 Nm, then tighten to an angle of 90°
8 ABS sensor (aWD models), before installation, clean the walls of the mounting hole and apply G052 112A3 grease to them
9 Hub assembly (aWD models)
10 Hub bolt (aWD models), subject to replacement, 70 Nm, then tighten to an angle of 90°
11 Shield bolts 5, 12 Nm
12 Hub assembly (fWD models)
13 Brake disc, replace both sides at the same time
14 Disc bolt 13, 4 Nm
15 Hub bolt (fWD models), subject to replacement, 180 Nm, then tighten to an angle of 180°
16 Brake pads, replaced in pairs, on both sides at the same time
17, 18 Anchor bracket, with guide pins and caps
19 Brake pad holders, must be replaced when replacing the pads
20 Support
21 Tube retainer 22
22 Brake pipe, 14 Nm
23 Parking brake cable
24 Self-locking bolt, subject to replacement, 35 Nm
25 Brake hose
3.1b Bosch BIRIII Rear Brake Parts (fWD and AWD models)
1 Hub assembly bolts 10, subject to replacement, 70 Nm, then tighten to an angle of 90°
2 ABS sensor (fWD models), before installation, clean the walls of the mounting hole and apply G052 112A3 grease 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), subject to replacement, 180 Nm, then tighten to an angle of 180°
8 Brake mechanism shield; on FWD // DI/D models - respectively with 3 // 4 mounting holes
9 Shield bolts 8, 12 Nm
10 Hub assembly (aWD models)
11 Hub bolt (aWD models), subject to replacement, 70 Nm, then tighten to an angle of 90°
12 Brake disc, replace both sides at the same time
13 Disc bolt 12, 4 Nm
14 Brake pads, replaced in pairs, on both sides at the same time
15 Anchor bracket, with guide pins and caps
16 Brake pad holders, must be replaced when replacing the pads
17 Support
18 Self-locking bolts, subject to replacement, 35 Nm
19 Parking brake cable
20 Hose retainer 21
21 Brake hose, with union nut and hollow bolt, 35 Nm
22 Hub assembly holder (fWD models)
23 Bracket bolts 15, subject to replacement, 90 Nm, then tighten to an angle of 90°
Replacing the pads
Note: Brake pads should be replaced in pairs and on both wheels of the same axle at the same time.
Note: If the pads are not being removed for replacement, i.e. will be reinstalled, mark them before removal so that they can be reinstalled in their original locations.
2. Jack up the car and place it on supports. Remove the rear wheel.
3. Remove the caliper mounting bolts while holding the guide pins with an open-end wrench (see accompanying illustration). Remove the caliper from the anchor bracket without disconnecting the brake hose from it, and secure the caliper to the wire, preventing tension on the hose.
3.3 Unscrewing the caliper mounting bolts (using CII-41 as an example)
4. Remove the brake pads and their retaining plates (see accompanying illustration).
3.4 Brake pad retaining plates (using CII-41 as an example)
5. Before installing the pads, press the piston into the brake wheel cylinder using a suitable tool (see accompanying illustration). Do not damage the piston dust 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 Pressing in the piston
6. Thoroughly clean the caliper and mating surfaces of the pads. If there is a protective coating on the new pads, remove it. Use only methylated spirits for cleaning, do not blow dust off the brake pads with compressed air.
7. Install the pads with retaining plates into the caliper. If new pads are being installed, use new retaining plates. Make sure that the pads are correctly positioned 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. Keep the guide pins from turning while doing this.
Note: New self-locking bolts (4 pcs.) are included in the repair kit.
9. Install the wheels and, with the vehicle stationary, press the brake pedal hard several times until the pads reach their working position.
10. Correct the brake fluid level.
Removal and installation, repair of the caliper
11. Jack up the car and place it on supports. 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 nipple on the caliper, lower the other end of this hose into a container to collect the brake fluid. Open the bleed nipple, press the brake pedal with the VAG1869/2 tool (or ask an assistant), close the bleed nipple and disconnect the hose.
14. Disconnect the brake caliper line.
15. Remove the caliper mounting bolts while holding the guide pins with an open-end wrench (see illustration 3.3).
16. Remove the caliper from the anchor bracket. If the caliper needs repair, (piston replacement) please refer to the accompanying illustrations.
3.16a Rear Brake Caliper Parts 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 Bleed nipple, 10 Nm, before installation lightly lubricate the thread with sealant G052 150A2
4 Self-locking bolt, subject to replacement, 35 Nm
5 Guide pin, lubricate before installation
6 Dust cover, stretches over bracket 7 and finger 5
7 Anchor bracket with guide pins and their dust boots
8 Anchor bracket with guide pins and their dust boots, installed with the load facing down
9 Dust cover, pulled by the outer sealing lip onto the piston
10 Piston with automatic regulator, before installation apply a thin layer of grease G052 150A2
11 Cuff
3.16b Bosch BIRIII Rear Brake Caliper Parts
1-7 see captions to illustration 3.16a
8 Dust cover, pulled by the outer sealing lip onto the piston
9 Piston with automatic regulator, before installation apply a thin layer of grease G052 150A2
10 Cuff
17. Follow the steps described in paragraphs 5-7.
18. Connect the brake line to the caliper and bleed the brake hydraulic system.
19. Connect and adjust the parking brake cable (see section 4).
20. Perform the actions described in paragraphs 9-10.