mK5 Jetta Brakes

Front brake caliper, servicing
Volkswagen Golf 5 2004-> VW Rabbit GTI 2006->

(A5)

Brake caliper FN 3, servicing
When carrying out repairs, install all parts supplied in

repair kit.
Only use mineral spirits to clean brake parts.
Apply thin coat of assembly paste G 052 150 A2 to

brake cylinders, pistons and seals.
1 - Dust cap
Install onto bleeder valve
2 - Bleeder valve, 10 Nm
Page 1 / 11
Apply a thin coat of assembly

paste G 052 150 A2 to the threads
before screwing in.
3 - Caps
Insert into bushing
4 - Guide pins, 30 Nm
5 - Bushing
Insert in brake caliper
6 - Brake caliper
7 - Brake carrier
Bolt to brake caliper
8 - Retaining spring
Insert with both ends in holes of

brake caliper
9 - Sealing ring
Removing and installing 47-1,

Brake caliper FN 3 piston,
removing and installing
10 - Piston

Apply thin coat of assembly paste

G 052 150 A2 to piston before
inserting
11 - Protective cap

Do not damage when inserting

piston
Brake caliper FN 3 piston, removing and installing
Special tools, testers and auxiliary items required
Page 2 / 11
Disassembly wedge 3409
Piston resetting tool T 10145
Assembly device for protective cap T 10146/6
Removing
- Force piston from brake caliper using compressed air.
Page 3 / 11
Set a piece of wood into the valley, so that the piston

is not damaged.
- Remove protective cap from brake caliper using Trim

Removal Wedge 3409 .
- Remove seal using Trim Removal Wedge 3409 .

When removing make sure that the surface of the cylinder
is not damaged.
Installing
- The surface of the piston and seal must only be cleaned

with mineral spirits and then dried.
Page 4 / 11
- Thinly coat piston and seal with assembly paste G 052

150 A2 before inserting.
- Install sealing ring in brake caliper.
- Insert protective cap - A - into assembly tool T 10146/6 1- .
- Press protective cap with assembly tool - 1 - and piston

resetting tool - 2 - into brake caliper so that it contacts the
brake caliper all around.
Check seating of protective caps:
- Protective cap must no longer be able to be pulled from

brake caliper by hand.
Page 5 / 11
- Press piston lightly against the protective cap and lock it

into position, e.g. with trim removal wedge - 2 - .
Do not angle piston, to avoid damaging the seal
sleeve.
- Blow protective cap on with pressurized air (max. 3 bar) 1 - . Protective cap springs on to piston.
- Press piston into brake caliper using piston resetting tool

- 1- .
The outer seal lip of the protective cap thereby slips into
the groove on the piston.
Brake caliper FNR-G, servicing

repair kit.

Page 6 / 11
1 - Dust cap
Install onto bleeder valve

before screwing in.
3 - Caps
Insert into bushing
4 - Guide pins, 30 Nm
5 - Bushing
Insert in brake caliper
6 - Brake caliper
Must not be bolted apart
Page 7 / 11
7 - Brake carrier
Bolt to brake caliper
8 - Retaining spring
Insert in brake pad retaining spring

and press below brake carrier
9 - Sealing ring

Brake caliper FNR-G piston,
10 - Piston


inserting
11 - Protective cap

Do not damage when inserting

piston
Brake caliper FNR-G piston, removing and installing
Disassembly wedge 3409
Page 8 / 11
Piston resetting tool T 10145
Assembly device for protective cap T 10146/6
Removing
- Force piston from brake caliper using compressed air.
Set a piece of wood into the valley, so that the piston

is not damaged.
- Remove protective cap from brake caliper using Trim
Removal Wedge 3409 .
Page 9 / 11

When removing, make sure that the surface of cylinder is
not damaged.
Installing

- Install sealing ring in brake caliper.
- Insert protective cap - A - into assembly tool T 10146/1 1- .
Page 10 / 11
- Press protective cap using assembly tool - 1 - and piston

resetting tool - 2 - into brake caliper so that it contacts the
brake caliper all around.
Check seating of protective caps:
- Protective cap must no longer be able to be pulled from
brake caliper by hand.
- Lightly press piston against protective cap with an

extension and ratchet adapter - 1 - and hold it there, in
that position.
Do not angle piston, to avoid damaging the seal
sleeve.
- Blow protective cap on with pressurized air (max. 3 bar) 2 - . Protective cap springs on to piston.
- Press piston with hand into brake caliper, possibly push
back slightly with piston resetting tool.
The outer seal lip of protective cap slips into groove on
piston.
Page 11 / 11
Rear brake caliper, servicing
Page 1 / 7
47 - 2

repair kit.
New brake calipers are filled with brake fluid and

pre-bled.

When carrying out repairs it is essential to

appropriately pre-bleed the brake calipers (without
brake pads) before installing in the vehicle 47-2,
Pre-bleeding brake caliper .
CII 41 brake assembly overview:

15 inch from KW 32/04
Page 2 / 7
Volkswagen Technical Site: http://volkswagen.msk.ru http://vwts.info http://vwts.ru

Volkswagen, Skoda, Seat, Audi
1 - Brake caliper with parking brake

cable lever
Replace brake caliper if leaking at

parking brake cable lever
Pre-bleed brake caliper after

repairing 47-2, Pre-bleeding
brake caliper
2 - Dust cap

before screwing in.
4 - Hex bolt, self-locking, 35 Nm
Replace
When loosening and tightening
Page 3 / 7
counter hold on guide pin

5 - Guide pin with stepping
Shorter than item 6
Grease before pulling on protective

cap
6 - Guide pins
Longer than item 5
Grease before pulling on protective

cap
7 - Protective cap
Pull onto brake carrier and guide

pin
8 - Brake pad with damper
Supplied as replacement part

assembled with sufficient grease
on guide pins
If protective caps or guide pins are

damaged use repair kit. Use
supplied grease packet to lubricate
guide pins.
9 - Protective cap
Pull outer sealing lip onto piston
Removing and installing

Removing
47-2,
10 - Piston with automatic adjustment

Removing
47-2,

inserting
11 - Sealing ring

Removing
Removing
47-2,
Resetting Extracting Tool T10165
Trim Removal Wedge 3409
- Remove piston from brake caliper by turning knurled

wheel toward left.
Insert reset and remove tool so that collar makes contact

on piston.
If the piston is difficult to move, use a 13 mm open

end wrench on the flats - arrow A - provided for this
Page 4 / 7
purpose.

Installing

- Place protective seal with outer sealing lip on the piston.

- Insert inner sealing lip in cylinder groove with assembly
wedge 3409.
Page 5 / 7
Hold piston in front of brake caliper for this procedure.

- Screw piston into housing by turning knurled wheel
clockwise.
- Use special tool 10165/1 for assistance when installing.
Insert reset and screw out tool so that collar makes

contact on brake caliper.
The automatic adjustment in brake caliper is

destroyed when piston is moved with piston resetting
tool (e.g. T 10145) or foot brake is operated.
Pre-bleeding brake caliper
Page 6 / 7
- Open bleeder valve - arrow A - and fill with brake fluid

using standard bleeder bottle until brake fluid flows out of
threaded hole (end of brake hose) - arrow B - without
bubbles. Close bleeder valve.
Position brake caliper as illustrated to pre-bleed.
Page 7 / 7
Pressure leak test
Page 1 / 1
47 - 3
Pressure leak test

Brake pressure gauge 0-250 bar V.A.G 1310 A
Adapter M 10 V.A.G 1310/6
Test conditions:
Brake system (hydraulic unit, brake hoses, brake lines and

brake calipers) operating properly and free of leaks.
- Remove bleeder valve at one front brake caliper.
Connect Brake Pressure Gauge 0-250 Bar VAG1310A
and bleed.
- Apply pressure to brake pedal until gauge indicates a
pressure of 50 bar. The pressure must not drop by more
than 4 bar during test period of 45 seconds. Replace
master cylinder if pressure drops greatly.
Bleeding braking system
Page 1 / 4
47 - 4

Description covers bleeding of brake system using the
brake filler and bleeder tool VAS 5234 and V.A.G
1869 .
Note:
Bleeding the braking system on vehicles with ABS is

carried out as for vehicles with conventional braking
systems.
Only use new brake fluid conforming to US standard

FMVSS 116 DOT 4.
Genuine VW/Audi brake fluid conforms to this

specification.
Brake fluid is poisonous. Also due to its corrosive

effect brake fluid must not come into contact with
paintwork.
Brake fluid is hygroscopic, which means it absorbs

moisture from the ambient air and should always be
stored in air tight containers.
Rinse off spillages, by using plenty of water.
There must be a positive pressure of 2 bar to bleed the

hydraulic unit.
Brake system, bleeding using brake filler and bleeder
tool VAS 5234
Brake filler/bleeder unit VAS 5234
Brake filler/bleeder unit suction adapter V.A.G

1869/4
Note:
On vehicles with EDL, EDL/ASR or EDL/ASR/ESP,

the brake system must be pre-bled when a chamber
in the brake fluid reservoir is completely empty (e.g.
brake system leaking).
- Remove rear wheels.

Pre-bleed:
- Connect Brake filler/bleeder unit VAS 5234 .

Bleeding sequence:
1 - Bleed left front and right front brake caliper together
simultaneously
2 - Bleed left rear and right rear brake caliper together
simultaneously
- With bleeder bottle hoses attached, leave bleeder valves
open long enough that brake fluid exits without bubbles.
The hydraulic unit must be bled again with tester VAS
5051 via function "Basic settings" .
Initiate basic setting (to bleed brake system):
VAS 5051 , connecting and selecting functions 45-3,
Connecting Vehicle Diagnostic, Testing and Information
System VAS 5051 and selecting functions .
- Then bleed brake system
Page 2 / 4
Bleeding (normal):
Adhere strictly to work sequence when bleeding brake

system.
- Connect Brake filler/bleeder unit VAS 5234 .
- Open bleeder valves in prescribed sequence and bleed
brake caliper.
1 - Left front brake caliper
2 - Right front brake caliper
3 - Left rear brake caliper
4 - Right rear brake caliper
Use suitable bleeder hose. It must fit tightly on bleeder
valve so that no air can enter brake system.
- With bleeder bottle hose attached, leave bleeder valve
open long enough that brake fluid exits without bubbles.
Subsequent bleeding
A second technician is required to assist:

- Depress brake pedal forcefully and hold.
- Open bleeder valve at brake caliper.
- Press brake pedal down onto stop.
- Close bleeder valve with pedal held down.
- Release brake pedal slowly.
This bleeding procedure must be performed 5 times
per brake caliper.
Bleeding sequence:
1 - Left front brake caliper
2 - Right front brake caliper
3 - Left rear brake caliper
4 - Right rear brake caliper
A road test must be performed after bleeding. During
this, at least one ABS regulation must be performed!
- Install rear wheels.
Torque specification for wheel bolts
Page 3 / 4
Repair Manual, Suspension, Wheels, Steering, Repair

Group 44, Torque specifications for wheel bolts
.
Changing brake fluid (every 2 years)
Changing brake fluid
Repair Manual, Maintenance
Page 4 / 4
Brake booster/brake master cylinder, assembly overview
Page 1 / 7
47 - 5
Brake booster/brake master cylinder, assembly

overview
Note:
Use only new brake fluid. Observe information on

brake fluid reservoir!
Pedal assembly
Hex nut, self-locking, 25 Nm
Replace each time
Gasket
For brake booster
Brake booster
On gasoline engines the

vacuum required is taken
from the intake manifold.
Some vehicles with gasoline

engine and automatic
transmission are equipped
with a Brake System
Vacuum Pump V192
475, Brake system vacuum
pump V192 .
On vehicles with HBV, a

vacuum sensor is installed
45-8, Brake Booster
Vacuum Sensor G483 ,
Functional check:
- With engine switched off,

depress brake pedal firmly
several times (to exhaust
the vacuum in the unit).
- Depress brake pedal with
average foot pressure, hold
and start engine. If booster
unit is working properly, the
pedal will be felt to give
slightly under foot (booster
assist becomes effective).
If faulty, replace completely.

47-7, Brake booster,
Sealing ring
Brake Booster Vacuum Sensor

G483
Only on vehicles with HBV

45-8, Brake Booster Vacuum
Sensor G483 , removing and
installing
Page 2 / 7
Brake master cylinder without

brake light switch
Application Electronic
Parts Catalog (ETKA)
Cannot be repaired. If faulty,

replace completely.

47-6, Brake master cylinder,
Brake master cylinder with brake

light switch
Application Electronic
Parts Catalog (ETKA)
Cannot be repaired. If faulty,

replace completely.

47-6, Brake master cylinder,
Brake light switch F
Includes Brake Pedal Switch

F47
On vehicles before KW
45/05, Brake Light Switch F
is located on brake pedal
46-4, Brake pedal, assembly
overview

46-4, Brake pedal, assembly
overview
Inner Torx bolt, 5 Nm
Heat shield
Hex nut, self-locking, 25 Nm
Replace each time it is

removed
Brake line, 14 Nm
Page 3 / 7
Brake line, 14 Nm
Brake master
cylinder/secondary piston
circuit to hydraulic unit
Brake master
cylinder/primary piston circuit
to hydraulic unit
Sealing plug
Moisten with brake fluid and

press into brake fluid
reservoir
Brake fluid reservoir
Cap
Sealing plug
Connection for vacuum hose
Vacuum hose
Insert into brake booster
Check-valve, checking
The check valve - A - must allow air through in

direction of - arrow - .
Check-valve must remain closed for opposite

direction.
Page 4 / 7
Observe correct installation position!

Brake system vacuum pump V192
Component location of Brake System Vacuum Pump V192

is located on automatic transmission at front in direction of
travel.
Servicing work on brake system vacuum pump V192 is not
possible. If there is a malfunction, replace Brake System
Vacuum Pump V192 .
Can be checked in "Guided Fault Finding" using VAS
5051
Removing
- Disconnect vacuum hose - 1 - from Brake System

Vacuum Pump V192 .
- Disconnect harness connector - 2 - for Brake System
Vacuum Pump V192 .
- Remove remaining harness connectors and wires from
bracket - 3 - .
- Remove - arrows - bracket - 3 - with Brake System
Vacuum Pump V192 .
Page 5 / 7
Page 6 / 7
- Remove - arrows - Brake System Vacuum Pump V192

- 1 - from bracket - 2 - .
Installing
Installation is in reverse order of removal.

Torque specifications:
Brake System Vacuum Pump V192 to bracket
Bracket to automatic transmission
Brake Light Switch F from KW 45/05, removing and
installing
On vehicles before KW 45/05, brake light switch was

located on brake pedal.
Removing
- Remove engine cover.
- On some vehicles, intake hose must be removed.
- Disconnect connector - 1 - from Brake Light Switch F .

- Remove bolt - 2 - from brake master cylinder.
- Pull Brake Light Switch F - 3 - downward and off from
8 Nm
25 Nm
Page 7 / 7
the brake master cylinder and remove it from the retaining

tab at the top - 4 - .
Installing
- Installation is in reverse order of removal.
Tightening torque:
Torx bolt to brake master cylinder
5 Nm
Brake master cylinder, removing and installing
Page 1 / 3
47 - 6
Special tools, testers and auxiliary items

required
Hose clamps up to 25 mm dia.

3094
Torque wrench V.A.G 1331
Brake filler/bleeder unit V.A.G

1869
Brake filler/bleeder unit suction

adapter V.A.G 1869/4
Brake filler/bleeder unit VAS

5234
Removing
- Note or request radio code on vehicles with coded radio if

necessary.
- Disconnect battery.
Repair Manual, Electrical Equipment, Repair Group 27,

Batteries, disconnecting and connecting
- Battery, removing and installing.

Batteries, removing and installing
.
- Remove battery carrier.
- Place sufficient lint-free cloths in area of engine and
transmission.
- Extract as much brake fluid as possible from brake fluid
reservoir using Brake filler/bleeder unit VAS 5234 or
extraction device V.A.G 1869/4 .
For vehicles with manual transmission:
- Disconnect clutch master cylinder supply hose - B using Hose Clamps Up to 25 mm dia. 3094 .
- Pull off supply hose - B - for clutch master cylinder.
Page 2 / 3
Page 3 / 3
Continued for all vehicles:

- Disconnect connector - A - from floating warning
indicator sensor.
- Disconnect connector from Brake Light Switch F (only on
vehicles from KW 45/05).
- Remove brake fluid reservoir. To do this press locking

tabs on the reservoir outward and simultaneously pull
brake fluid reservoir out of sealing plugs.
- Unfasten brake lines - 1 - at brake master cylinder and
plug brake lines with sealing plugs from repair kit Part No.
1H0 698 311 A.
- Remove nuts - 2 - from main brake cylinder.
- If present, remove heat shield.
- Carefully take brake master cylinder out of brake
booster.
Installing

Observe the following points when installing:
- When installing together the brake master cylinder and
brake booster, make sure that the push rod is correctly
located in the brake master cylinder.
- Bleed braking system
47-4, Bleeding braking system
Master brake cylinder at brake booster
25 Nm
Use new nuts!
Brake lines to main brake cylinder
14 Nm
Brake booster, removing and installing
Page 1 / 5
47 - 7
Special tools, testers and auxiliary items

required
Hose clamps up to 25 mm dia.

3094
Torque wrench V.A.G 1331
Brake filler/bleeder unit V.A.G

1869
Brake filler/bleeder unit suction

adapter V.A.G 1869/4
Brake filler/bleeder unit VAS

5234
Removing
- Note or request radio code on vehicles with coded radio if

necessary.
- Disconnect battery.

Batteries, disconnecting and connecting
- Battery, removing and installing.

Batteries, removing and installing
.
- Remove battery carrier.
- Place sufficient lint-free cloths in area of the engine and
transmission.
- Extract as much brake fluid as possible from brake fluid
reservoir using Brake filler/bleeder unit VAS 5234 or
extraction device V.A.G 1869/4 .
- Disconnect clutch master cylinder supply hose - B using Hose Clamps Up to 25 mm dia. 3094 .
- Pull off supply hose - B - for clutch master cylinder.
Page 2 / 5

- Disconnect connector - A - from floating warning
indicator sensor.
- Disconnect connector from Brake Light Switch F (only on
vehicles from KW 45/05).
- Remove brake fluid reservoir. To do this press locking

tabs on reservoir outward and simultaneously pull brake
fluid reservoir out of sealing plugs.
- Unfasten brake lines - 1 - at brake master cylinder and
plug brake lines with sealing plugs from repair kit Part No.
1H0 698 311 A.
- Remove nuts - 2 - from brake master cylinder.
- If present, remove heat shield.
- Carefully take brake master cylinder out of brake
booster.
- Pull vacuum hose out of brake booster.
- Remove cable - 1 - , unscrew mounting bracket - 2 and lay it aside.
Page 3 / 5
Page 4 / 5
Repair Manual, Manual Transmission, Repair Group 34,

Selector mechanism, servicing
- Remove trim on drivers side.
Repair Manual, Body Interior, Repair Group 70,

Instrument panel
Brake light switch is no longer present on mounting bracket
from KW 45/05.
- Disconnect connector - 1 - from brake light switch.

- Remove Brake Light Switch - 2 - by rotating 45
left.
toward
- Remove air channel - 3 - .

- Remove cover - 4 - .
- Disconnect brake pedal from brake booster
Separating brake pedal from brake booster .
46-4,
Page 5 / 5
- Remove nuts - 1 - from brake booster.

- Loosen both upper nuts - 2 - from mounting bracket.
- Carefully remove brake booster from vehicle.
Installing

Observe the following when installing:
- Clip brake pedal together with brake booster
4
- After installing, bleed brakes
system and clutch.
Topic 46-
47-4, Bleeding braking
Only on vehicles up to KW 45/05:

- Adjust brake light switch 46-4, Brake light switch F up
to KW 45/05, removing, installing and adjusting .
Brake booster to foot pedal assembly/cross panel
Use new nuts!
Master brake cylinder at brake booster
25 Nm
25 Nm
Use new nuts!
Brake lines to main brake cylinder
14 Nm
Brake line repairs
Page 1 / 7
47 - 8
Brake line repairs

Flare brake lines with 5 mm outer diameter using brake line
flaring appliance VAS 6056 without damaging coating. In
this way, brake lines can be inexpensively partially
replaced in certain cases.
Work with brake line kit V.A.B. 1356 is not permitted
because of the coating and diameter of black brake lines.
Note:
Brake lines must not be bent more than 90 ,

otherwise they kink or deform causes unacceptable
constriction in the line.
Disconnect brake lines preferably at vehicle floor.
Position of intermediate pieces should be selected

so that they cannot rub against moving parts.
Do not lubricate spindle, clean only with mineral

spirits.
Brake line flaring appliance VAS 6056
Brake filler/bleeder unit VAS 5234
Brake line repairs
Listing of individual tools:
Flaring appliance VAS 6056/1
flaring jaws VAS 6056/6 are

contained in the flaring
appliance VAS 6056/1
Tube cutter VAS 6056/2
Brake line shearing tool VAS

6056/3
The threaded pins (in shaft

and at sides) are set and
must not be adjusted!
Self-grip pliers with plastic

clamping jaws VAS 6056/4
Page 2 / 7
Brake line repairs
Line bending tool VAS 6056/5
SW6 angle screwdriver
Flaring jaws VAS 6056/7
Flaring tool, assembly overview
Upper part of flaring tool
Hand grip mount
Remove to change flaring

jaws
Must be removed to reach

retaining screw for upper
part
Retaining screw
Page 3 / 7
Brake line repairs
For upper part of flaring tool
Flaring jaws threaded pins
Center and hold flaring jaws
2 mm hex socket head
Flaring jaws
Various
Assembly instructions 478, Flaring jaws assembly

instructions:
Flaring jaws assembly instructions:
VAS 6056/6 (dark) for black brake lines
VAS 6056/7 (light) for green brake lines
Note:
The arrow on the rounded side of the flaring jaws

must face toward edge of housing and the straight
side of the flaring jaws must be installed toward
spindle, otherwise flared head will not be formed
correctly.
Instructions
Page 4 / 7
Brake line repairs
- Remove affected brake line at brake caliper or wheel

brake cylinder and collect escaping brake fluid and dispose
of it correctly.
- Disconnect brake line at appropriate location (straight,

accessible part) with line cutter - 2 - .
- Remove piece to be exchanged.
- Lubricate brake line surface.
- Clamp brake line in self-grip pliers - 4 - so that 50 mm of

the plastic clamping jaws show.
- Clamp shearing tool - 3 - in a drill and place it on brake
line.
- Shear coating from brake line at a slow drill RPM and
with light pressure against the line.
The length of the sheared-off portion is determined by the
stop in the shearing tool.
- Remove shearing tool from brake line and remove
shearing remains.
Page 5 / 7
Brake line repairs
- Remove self-grip pliers and tube fitting - D - from brake

line.
- Slide brake line - B - against stop - A - in flaring tool.

Note:
Brake line must contact stop when hex socket heat

screws are tightened, otherwise flared head will not
be formed correctly.
- Clamp brake line in flaring tool until it cannot be moved

any more. Fold stop - A - up and tighten hex socket head
screws diagonally with angle screw driver - C - .
Page 6 / 7
Brake line repairs
Page 7 / 7
- Turn spindle to stop in flaring tool.

- Turn spindle back.
- Loosen hex socket head screws diagonally.
- Remove brake line from flaring tool, clean and check
brake line and flared head.
Briefly rinse part of brake line remaining in vehicle.
- Connect brake filler/bleeder unit VAS 5234 , place
bleeder container hose on flanged head of brake line and
run brake filler/bleeder unit VAS 5234 briefly until some
brake fluid runs through.
- Blow out brake line to be inserted with compressed air.
- Join brake lines with connecting piece - E - .

- Assemble brake line.
- Bleed braking system
47-4, Bleeding braking system

mK5 Jetta Brakes

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Front brake caliper, servicing

Volkswagen Golf 5 2004-> VW Rabbit GTI 2006->

Front brake caliper, servicing

When carrying out repairs, install all parts supplied in

Only use mineral spirits to clean brake parts.

Apply thin coat of assembly paste G 052 150 A2 to

Install onto bleeder valve

Front brake caliper, servicing

Apply a thin coat of assembly

Insert into bushing

Insert in brake caliper

Bolt to brake caliper

Insert with both ends in holes of

Removing and installing 47-1,

Removing and installing 47-1,

Apply thin coat of assembly paste

Removing and installing 47-1,

Do not damage when inserting

Brake caliper FN 3 piston, removing and installing

Special tools, testers and auxiliary items required

Front brake caliper, servicing

Disassembly wedge 3409

Piston resetting tool T 10145

Assembly device for protective cap T 10146/6

- Force piston from brake caliper using compressed air.

Front brake caliper, servicing

Set a piece of wood into the valley, so that the piston

- Remove protective cap from brake caliper using Trim

- Remove seal using Trim Removal Wedge 3409 .

- The surface of the piston and seal must only be cleaned

Front brake caliper, servicing

- Thinly coat piston and seal with assembly paste G 052

- Insert protective cap - A - into assembly tool T 10146/6 1- .

- Press protective cap with assembly tool - 1 - and piston

- Protective cap must no longer be able to be pulled from

Front brake caliper, servicing

- Press piston lightly against the protective cap and lock it

- Press piston into brake caliper using piston resetting tool

When carrying out repairs, install all parts supplied in

Only use mineral spirits to clean brake parts.

Apply thin coat of assembly paste G 052 150 A2 to

Front brake caliper, servicing

Install onto bleeder valve

Apply a thin coat of assembly

Insert into bushing

Insert in brake caliper

Must not be bolted apart

Front brake caliper, servicing

Bolt to brake caliper

Insert in brake pad retaining spring

Removing and installing 47-1,

Removing and installing 47-1,

Apply thin coat of assembly paste

Removing and installing 47-1,

Do not damage when inserting

Brake caliper FNR-G piston, removing and installing

Special tools, testers and auxiliary items required

Disassembly wedge 3409

Front brake caliper, servicing

Piston resetting tool T 10145

Assembly device for protective cap T 10146/6

- Force piston from brake caliper using compressed air.