TSB : Brake pads, removing and installing

Details

Special tools, testers and auxiliary items required Fig 1: Identifying Special Tools - Brake Pads, Removing And Installing Courtesy of VOLKSWAGEN UNITED STATES, INC. Torque wrench V.A.G 1331/ Torque wrench V.A.G 1332/ Piston resetting tool T10145 Interchangeable Head T40036 Vehicle Diagnosis, Testing and Information System VAS 5051 Removing NOTE: When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven! Operating the electromechanical parking brake after a long drive is recommended. Pad play is automatically adapted approximately every 1000 km. Set vehicle to vehicle lift mode. → 43 - Self Leveling Suspension Raise vehicle. Remove wheels. CAUTION: If brake pads are ceramics, wheel must not fall on brake disc, otherwise it will be irreparably damaged. To remove/install wheel, insert two assembly pins in wheel bolt mount. The long assembly pin is in the upper position. Fig 2: Data Link Connector (DLC) Courtesy of VOLKSWAGEN UNITED STATES, INC. With ignition switched off, connect Vehicle Diagnostic, Testing and Information System VAS 5051 with Diagnostic cable, 3 m with voltage supply VAS 50511 to 16-pin vehicle Data Link Connector (DLC) and select parking brake with "Address word" 53. NOTE: Ignition on Release parking brake Coding check and reported if necessary. DTC memory interrogated, errors shown corrected and DTC memory erased. Fig 3: Locating Control Module Identification With Code Indicated On Display Courtesy of VOLKSWAGEN UNITED STATES, INC. Shown on VAS 5051 display: Select function "53 - Parking brake". Select function "04 - Basic setting". Fig 4: Identifying Diagnostic Operation System VAS 5051A (Prompt For Entering Display Group Appears In Display Zone & Input Keypad Appears In Display Zone) Courtesy of VOLKSWAGEN UNITED STATES, INC. Shown on VAS 5051 display: The request to enter a display group number appears in display field - 1 -. An entry keypad is shown in display field - 2 -. When installing new brake pads Using entry keypad, enter in display field - 2 - the "05" or "005" for "Display group number one and confirm by pressing " Q button. (Reset pistons) When re-installing old brake pads Using entry keypad in display field - 2 - , enter "07" or "007" for "Display group number one and confirm by pressing " Q button. (brake opens completely, pad thickness does not need to be entered later) Affects all vehicles Fig 5: Removing/Installing Attachment Bolts From Brake Caliper Housing Courtesy of VOLKSWAGEN UNITED STATES, INC. Remove attachment bolts from brake caliper housing, to do so counter-hold guide pins. NOTE: Actuator or brake system connector must not be disconnected. Fig 6: Sliding Connector Out Of Bracket Courtesy of VOLKSWAGEN UNITED STATES, INC. Slide connector out of bracket Remove brake caliper sideways Remove brake pads Remove guide clamps NOTE: It is possible to change brake discs with brake carrier installed. Fig 7: Pressing Pistons Back Using Piston Resetting Tool T10145 Courtesy of VOLKSWAGEN UNITED STATES, INC. Press pistons back using Piston Resetting Tool T10145 Installing Clean brake caliper with mineral spirits exclusively. Fig 8: Inserting Pad Retaining Springs Courtesy of VOLKSWAGEN UNITED STATES, INC. Insert brake pad retaining springs Fig 9: Identifying Brake Pads, Guide Clips & Brake Caliper Housing Courtesy of VOLKSWAGEN UNITED STATES, INC. Insert brake pads. Fig 10: Identifying Brake Pads Are Located Correctly In Anti-Rattle Springs Courtesy of VOLKSWAGEN UNITED STATES, INC. Make sure that the brake pads are located correctly in anti-rattle springs - arrows -. Fig 11: Removing/Installing Attachment Bolts From Brake Caliper Housing Courtesy of VOLKSWAGEN UNITED STATES, INC. Secure brake caliper housing using new self-locking bolts. NOTE: The repair kit includes four self-locking hex bolts which must be installed in all cases. Fig 12: Installing Electronic Parking Brake Connector In Bracket Courtesy of VOLKSWAGEN UNITED STATES, INC. Install electronic parking brake connector in bracket. Fig 13: Identifying Diagnostic Operation System VAS 5051A (Prompt For Entering Display Group Appears In Display Zone & Input Keypad Appears In Display Zone) Courtesy of VOLKSWAGEN UNITED STATES, INC. Shown on VAS 5051 display: The request to enter a display group number appears in display field - 1 -. An entry keypad is shown in display field - 2 -. Using entry keypad, enter in display field - 2 - the "06" or "006" for "Display group number one and confirm by pressing " Q button. (guide pistons together) Press left Arrow button to leave basic setting. When installing new brake pads Fig 14: Identifying Diagnostic Operation System VAS 5051A (Prompt For Entering Display Group Appears In Display Zone & Input Keypad Appears In Display Zone) Courtesy of VOLKSWAGEN UNITED STATES, INC. Shown on VAS 5051 display: The request to enter a display group number appears in display field - 1 -. An entry keypad is shown in display field - 2 -. Press left arrow button 2 times Fig 15: Locating Control Module Identification With Code Indicated On Display Courtesy of VOLKSWAGEN UNITED STATES, INC. Shown on VAS 5051 display: Selection function "10 - Adaptation" Measure thinner brake pad without backing plate and enter value using keypad or scroll bars. Select keypad or enter via scroll bars Enter min - max value, between 10-23 mm using entry keypad in display field - 2 -. Confirm by pressing Q button (guide pistons together) Select Save and then Transfer. When re-installing used brake pads, procedure is changed Fig 16: Identifying Diagnostic Operation System VAS 5051A (Prompt For Entering Display Group Appears In Display Zone & Input Keypad Appears In Display Zone) Courtesy of VOLKSWAGEN UNITED STATES, INC. Shown on VAS 5051 display: The request to enter a display group number appears in display field - 1 -. An entry keypad is shown in display field - 2 -. Using entry keypad, enter in display field - 2 - the "05" or "005" for "Display group number one and confirm by pressing" Q button. Install wheels → 44 - Wheels, Tires and Wheel Alignment Check brake fluid level and top off if necessary. NOTE: The electronic parking brake must now be re-calibrated. Requirements Electronic parking brake must be released. Selector lever must be in "P" position. Switch ignition off, remove ignition key and lock steering wheel lock. The re-calibration is performed. The electronic parking brake audibly travels up and back down. The air gap adjusts itself. Wait until this process is completed. The re-calibration is now finished. The DTC memory is then erased.