Rear wheel brakes, servicing. Стр. 1 из 45. Note:

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1 Volkswagen Touareg - Rear wheel brakes, servicing Стр. 1 из Rear wheel brakes, servicing Rear brakes, FN 44 brake caliper, servicing Note: After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position. To siphon off brake fluid from the brake fluid reservoir, use the brake filler and bleeder unit VAS Before removing a brake caliper or disconnecting a brake hose, the brake pedal loading device V.A.G 1869/2 should be installed (to relieve pressure).

2 Стр. 2 из 45 Brake disc/brake drum Ventilated brake disc: diameter 314 mm Brake disc thickness: 22 mm Wear limit: 18 mm Brake drum: diameter 185 mm Wear limit 186 mm Must always be replaced together on both sides of axle To remove, first remove brake caliper and brake carrier, do not remove brake line

3 Стр. 3 из 45 Installed bolt, 20 Nm Brake disc to wheel hub Carrier Bolt to wheel bearing housing Hex head bolt, 200 Nm Brake pads Thickness 13 mm not including backing plate Wear limit: 2 mm not including backing plate With wear indicator When wear limit is reached (limit: approx. 4 mm) warning lamp lights up in instrument cluster Checking thickness Repair Manual, Maintenance Always replace both sides Removing and installing 46-2, Brake pads, removing and installing Retaining spring Brake caliper Do not disconnect brake lines to replace brake pads or brake discs Removing and installing 46-2, Brake caliper, removing and installing servicing 47-2, FN 44 brake caliper, servicing Retainer for brake pad wear

4 Стр. 4 из 45 indicator wiring Bolt, 10 Nm Guide pins, 30 Nm Cap Hex socket head bolt, 8 Nm Bracket Brake line with banjo fitting and hollow bolt, 38 Nm Do not disconnect brake lines to replace brake pads or brake discs Pin Spring Spring Installation location: at the adjusting nut Differences between tensioning spring Higher number of spring coils Easy to bend by hand Spring Installation location: at the expander Differences between tensioning spring Smaller number of spring coils Hard to bend by hand Brake shoe Removing and installing

5 Стр. 5 из , Brake shoes, removing and installing Minimum lining thickness 1 mm Checking thickness Expander Adjustment nut Adjusting parking brake 46-2, Parking brake, adjusting Carrier Rear brake cable Brake pads, removing and installing Special tools, testers and auxiliary items required Torque wrench V.A.G 1331 Piston resetting tool T10145

6 Стр. 6 из 45 Removing If reusing brake pads, mark location. Install in same position when installing otherwise uneven braking will occur! - Remove wheels. - Press retaining spring in direction of - arrow A - until it can be pressed out of bore in direction of - arrow B-. - Turn retaining spring clockwise - arrow - until it can be removed from upper bore.

7 Стр. 7 из 45 - Separate connector for brake pad wear indicator. - Remove wire for brake pad wear indicator from retainer on caliper. - Remove lower connector of brake wear indicator and wheel speed sensor from retainer on brake caliper. - Remove caps - arrows -. - Remove both guide pins - arrows - from brake caliper. - Remove brake caliper and suspend with wire so that the weight of the caliper does not cause any stress or damage to the brake line. - Remove brake pads. Cleaning: Warning! Do not blow brake system using compressed air, the dust produced is harmful to health! - Thoroughly clean contact surfaces for brake pads at brake carrier, remove corrosion. - Clean brake caliper.

8 Стр. 8 из 45 Clean brake caliper with mineral spirits exclusively. Installing Note: Before pressing the piston back to insert new brake pads, draw off brake fluid from the reservoir with a bleeder bottle. Otherwise, particularly if reservoir has been topped off, fluid will overflow and cause damage. - Press pistons back in with piston resetting tool T Note: The inner (piston side) brake pads are directional and specific to each side of the vehicle. They are designated by markings that show the direction of travel.

9 Стр. 9 из 45 Directional brake pads Note: In installed position, the arrow - A - on the backing plate of the brake pad points down (in rotation direction of brake disc). - Install brake pad by inserting retaining springs on pad into piston - arrows -. - Set outer brake pad onto carrier.

10 Стр. 10 из 45 - Attach brake caliper to carrier by fastening guide pins - arrows -. - Install both caps. - Press wheel speed sensor wiring into retainer on brake caliper. - Reconnect connectors and for brake wear indicator in retainer on brake caliper. - Secure brake wear indicator wiring in retainer on brake caliper. - Install retaining spring into upper bore - arrow - and turn down in direction of - arrow -.

11 Стр. 11 из 45 - Set retaining spring on bottom of carrier. - First press retaining spring in direction of - arrow A -, then at the same time into bore of brake caliper in direction of - arrow B -. - Install wheels. Tightening torque specification for wheel bolts Repair Manual, Suspension, Wheels, Steering, Repair Group 44, Tightening torques for wheel bolts Note: After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position. After changing brake pads check brake fluid level. Tightening torque Brake caliper to carrier 30 Nm Brake caliper, removing and installing Special tools, testers and auxiliary items required

12 Стр. 12 из 45 Torque wrench V.A.G 1331 Brake pedal depressor V.A.G 1869/2 Removing This work sequence is only necessary for replacing, or for after servicing, brake caliper. - Remove wheels. - Press retaining spring in direction of - arrow A - until it can be pressed out of bore in direction of - arrow B-.

13 Стр. 13 из 45 - Turn retaining spring clockwise - arrow - until it can be removed from upper bore. - Separate connector for brake pad wear indicator. - Remove wire for brake pad wear indicator from retainer on caliper. - Remove lower connector of the brake wear indicator and wheel speed sensor from retainer on brake caliper. - Press bleeder bottle hose onto bleeder valve of brake caliper and then open bleeder valve. - Install brake pedal loading device V.A.G 1869/2. - Close bleeder valve and remove bleeder bottle. - Disconnect brake line.

14 Стр. 14 из 45 - Remove caps - arrows -. - Remove both guide pins - arrows - from brake caliper. - Remove brake caliper from carrier. - Remove brake pads from brake caliper. Installing The piston is pushed back. The outer brake pad sits on carrier. - Set inner brake pad with retaining springs into brake caliper (piston). Note: The inner (piston side) brake pads are directional and specific to each side of the vehicle. They are designated by markings that show the direction of travel.

15 Стр. 15 из 45 Directional brake pads Note: In installed position, the arrow - A - on the backing plate of the brake pad points down (in rotation direction of brake disc). - Attach brake caliper to carrier by fastening guide pins - arrows -. - Install both caps. - Connect brake line to brake caliper. - Remove brake pedal loading device V.A.G 1869/2.

16 Стр. 16 из 45 - Press wheel speed sensor wiring into retainer on brake caliper. - Reconnect connectors and for brake wear indicator in retainer on brake caliper. - Secure brake wear indicator wiring in retainer on brake caliper. - Install retaining spring into upper bore - arrow - and turn down in direction of - arrow -. - Set retaining spring on bottom of carrier. - First press retaining spring in direction of - arrow A -, then at the same time into bore of brake caliper in direction

17 Стр. 17 из 45 of - arrow B -. - Bleed brake system 47-4, Bleeding braking system. - Install wheels. Tightening torque specification for wheel bolts Repair Manual, Suspension, Wheels, Steering, Repair Group 44, Tightening torques for wheel bolts Note: After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position. Check brake fluid level. Tightening torques: Guide pins to carrier Brake line with banjo fitting and hollow bolt to brake caliper 30 Nm 38 Nm Brake shoes, removing and installing Special tools, testers and auxiliary items required Hook 3438 Removing - Remove wheels. - Remove brake pads 46-2, Brake pads, removing and installing.

18 Стр. 18 из 45 - Remove carrier. - Turn brake disc until parking brake adjustment nut is visible through one of the lug bolt holes. Parking brake, resetting: - Turn adjustment nut - A - against the resistance of tension spring - B -. - Remove brake disc/brake drum. - Remove springs. - Remove pins with springs and remove brake shoes. Installing Installation is in reverse order of removal. - Adjusting parking brake 46-2, Parking brake, adjusting. Rear brakes, Brembo (1KF) brake caliper, servicing Installation date: to KW 22/06 Note: After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position. To siphon off brake fluid from the brake fluid reservoir, use the brake filler and bleeder unit VAS Before removing a brake caliper or disconnecting a brake hose, the brake pedal loading device V.A.G

19 Стр. 19 из /2 should be installed (to relieve pressure). Brake disc/brake drum Ventilated brake disc: diameter 330 mm Brake disc thickness: 28 mm Wear limit: 26 mm Brake drum: diameter 210 mm Wear limit 211 mm Must always be replaced together on both sides of axle To remove, first remove brake caliper, do not remove

20 Стр. 20 из 45 brake line Installed bolt, 14 Nm Brake disc to wheel hub Hex bolt, 14 Nm For adjustment of parking brake Brake caliper Do not disconnect brake line when changing brake discs Removing and installing 46-2, Brake caliper, removing and installing Servicing 47-2, Brembo 17" brake caliper, servicing Multiple point socket head bolt, 150 Nm plus an additional 90 ( 1 / 4 turn) Always replace Torx screw Protective plate Brake pads Thickness 11 mm not including backing plate Wear limit: 2 mm not including backing plate With wear indicator When wear limit is reached (limit: approx. 4 mm) warning lamp lights up in instrument cluster Checking thickness: Repair Manual, Maintenance

21 Стр. 21 из 45 Always replace both sides Removing and installing 46-2, Brake pads, removing and installing Brake pad wear indicator wiring Securing clip Retaining pin Retaining spring Bracket Bolt to brake caliper housing Hex bolt, 8 Nm Spring clip Brake line, 14 Nm Do not disconnect brake line when changing brake discs Brake hose Do not disconnect brake line when changing brake discs Make sure that lugs are properly seated in grooves in bracket. Pin Spring Spring Location: at the adjusting nut Differences between tensioning spring Item : Higher number of spring coils Easy to bend by hand

22 Стр. 22 из 45 Spring Location: at the expander Differences between tensioning spring Item : Smaller number of spring coils Hard to bend by hand Expander Adjustment nut Adjusting parking brake 46-2, Parking brake, adjusting Brake shoe Removing and installing 46-2, Brake shoes, removing and installing Minimum lining thickness 1 mm Checking thickness Carrier Rear brake cable Brake pads, removing and installing Special tools, testers and auxiliary items required

23 Стр. 23 из 45 Piston resetting tool T10145 Removing Note: If reusing brake pads, mark location. Install in same position when installing otherwise uneven braking will occur! - Remove wheels. - Separate connector for brake pad wear indicator.

24 Стр. 24 из 45 - Pull securing clip - arrow - out of pad retaining pin. - Press retaining spring inward - arrow - while pulling out retaining pin Pull brake pad wear indicator wire out of brake caliper housing and out of retaining spring Remove retaining spring. Note: Before pressing brake pads back, draw off brake fluid from reservoir using a bleeder bottle. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage.

25 Стр. 25 из 45 - Press brake pads away from brake disc and then remove from brake caliper housing. - If the brake pads are to be replaced, the brake wear indicator sensor and wires are carefully taken out of the brake pads and checked for damages. Use brake wear indicator sensor and wire if they are not damaged. Cleaning: Warning! Do not blow brake system using compressed air, the dust produced is harmful to health! - Clean brake caliper. Clean brake caliper with mineral spirits exclusively. Installing Note: Before pressing piston into cylinder using piston resetting tool, brake fluid must be extracted from brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage. - Press pistons back. - Install brake pad wear indicator sensor carefully into new brake pad. - Insert brake pads into brake caliper housing.

26 Стр. 26 из 45 - Insert retaining spring Insert brake wear indicator wire under retainer in the retaining spring and into brake caliper housing - arrows -. - Press retaining spring inward - arrow - and drive in retaining pin onto limit stop. - Secure pad retaining pin with securing clip - arrow-.

27 Стр. 27 из 45 - Reconnect connector for brake wear indicator to connection on bracket on wheel bearing housing. - Install wheels Repair Manual, Suspension, Wheels, Steering, Repair Group 44, Tightening torques for wheel bolts Note: After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position. After changing brake pads check brake fluid level. Brake caliper, removing and installing Special tools, testers and auxiliary items required Torque wrench V.A.G 1332

28 Стр. 28 из 45 Socket insert SW 16 T10198 Brake pedal lading device V.A.G 1869/2 Removing This work sequence is only necessary for replacing, or for after servicing, brake caliper. - Remove wheels. - Press bleeder bottle hose onto bleeder valve of brake caliper and then open bleeder valve. - Install brake pedal loading device V.A.G 1869/2. - Close bleeder valve and remove bleeder bottle. - Remove brake line from brake caliper. - Remove brake pads 46-2, Brake pads, removing and installing. - Remove wheel speed sensor wiring from retainer on brake caliper - Remove brake caliper from wheel bearing housing.

29 Стр. 29 из 45 Installing - Install brake caliper to wheel bearing housing. - Install brake pads 46-2, Brake pads, removing and installing. - Install brake line to brake caliper. - Press wheel speed sensor wiring into retainer on brake caliper. - Remove brake pedal loading device V.A.G 1869/2. - Bleed brake system 47-4, Bleeding braking system. - Install wheels. Tightening torque specification for wheel bolts Repair Manual, Suspension, Wheels, Steering, Repair Group 44, Tightening torques for wheel bolts Note: After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position. Check brake fluid level. Tightening torques: Socket head bolt to wheel bearing housing. 150 Nm plus an additional 90 (1/4 turn) Use new bolts! Brake line to brake caliper 14 Nm Brake shoes, removing and installing Special tools, testers and auxiliary items required

30 Стр. 30 из 45 Hook 3438 Socket insert SW 16 T10198 Removing - Remove wheels. - Remove the brake pads 46-2, Brake pads, removing and installing. - Remove wheel speed sensor wiring from retainer on brake caliper - Remove the brake caliper bolts. - Remove brake caliper and suspend with wire so that the weight of the caliper does not cause any stress or damage to the brake line.

31 Стр. 31 из 45 - Remove the hex bolt - arrow - for parking brake adjustment nut. Parking brake, resetting: - Turn the adjustment nut - A - against the resistance of the tension spring - B -. - Remove the brake disc/brake drum. - Remove the springs. - Remove the pins with the springs and remove the brake shoes. Installing Installation is in reverse order of removal. - Adjusting parking brake 46-2, Parking brake, adjusting. Rear brakes, Brembo (1KQ) brake caliper, servicing Installation date: from KW 22/06 Note: After replacing brake pads, depress brake pedal

32 Стр. 32 из 45 firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position. Use brake filler bleeder unit VAS 5234 or to extract brake fluid from brake fluid reservoir. Before removing brake caliper or disconnecting brake hose, brake pedal actuator V.A.G 1869/2 must be inserted (this dissipates pressure). Brake disk/brake drum Internally ventilated brake disc: dia. 330 mm Brake disc thickness: 28 mm Wear limit: 26 mm

33 Стр. 33 из 45 Brake drum: dia. 210 mm Wear limit: 211 mm Must always be replaced together on both sides of axle To remove, first remove brake caliper, do not remove brake line Installed bolt, 14 Nm Brake disc to wheel hub Hex bolt, 14 Nm For adjustment nut of parking brake Brake caliper Do not remove brake line when replacing brake disc Removing and installing 46-2, Brake caliper, removing and installing Servicing 47-2, Brembo 17" brake caliper, servicing Multi-point socket head bolt, 150 Nm plus an additional 90 ( 1 / 4 turn) Always replace after removal Brake pads Thickness: 11 mm without backing plate Wear limit: 2 mm without backing plate With wear indicator When wear limit is reached

34 Стр. 34 из 45 (limit: approx. 4 mm), the warning lamp lights up in instrument cluster Checking thickness: Repair Manual, Maintenance Must always be replaced together on both sides of axle Removing and installing 46-2, Brake pads, removing and installing Wire for brake pad wear indicator Pad retaining pin Retaining spring Bracket Fasten to brake caliper housing Hex bolt, 8 Nm Spring clamp Brake line, 14 Nm Do not remove brake line when replacing brake disc Brake hose Do not remove brake hose when replacing brake disc Make sure that lugs are properly seated in grooves in bracket. Spring dowel sleeve Compression spring Pull-spring Component location: At

35 Стр. 35 из 45 adjustment nut Distinguishing characteristics compared to pull-spring Item : Larger number of spring coil Can be easily bent by hand Pull-spring Component location: At spreader Distinguishing characteristics compared to pull-spring Item : Smaller number of spring coil Cannot be easily bent by hand Spreader Adjustment nut Adjust parking brake 46-2, Parking brake, adjusting Brake shoe Removing and installing 46-2, Brake shoes, removing and installing Minimum pad thickness 1 mm Checking thickness Brake carrier Rear brake cable Brake pads, removing and installing Special tools, testers and auxiliary items required

36 Стр. 36 из 45 Piston resetting tool T10145 Removing Note: When removing, mark brake pads that will be used again. Install in the same position, otherwise braking effect will be uneven! - Remove wheels. - Disconnect connector for brake pad wear indicator.

37 Стр. 37 из 45 - Drive out pad retaining pins - arrows -. - Pull wire for brake pad wear indicator out of brake caliper housing and out of retaining spring Remove retaining spring. Before pressing brake pads back, draw off brake fluid from reservoir using a bleeder bottle. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage. - Press brake pads off brake disc and remove from brake caliper. - If brake pads are to be replaced, carefully remove sensor with wire for brake pad wear indicator from brake pads and check for damages. Reuse undamaged sensors and wires. Cleaning: Warning! Do not blow brake system using compressed air, the dust produced is harmful to health! - Clean brake caliper.

38 Стр. 38 из 45 Use only appropriate solvents for cleaning brake caliper. Installing Note: Before pressing piston into cylinder using piston resetting tool, brake fluid must be extracted from brake fluid reservoir. Otherwise, especially if reservoir has been topped off, fluid will overflow and cause damage. - Press pistons back. - Carefully install sensor for wire of brake pad wear indicator into new brake pads. - Insert brake pads into brake caliper housing. - Insert retaining spring Install wire for brake pad wear indicator below tab of retaining spring and in brake caliper housing - arrows-. - Press retaining spring down and place pad retaining pin in brake caliper.

39 Стр. 39 из 45 - Drive pad retaining pins - arrows - into brake caliper as far as stop. - Connect connectors of brake pad wear indicator in bracket of brake caliper housing. - Install wheels Repair Manual, Suspension, Wheels, Steering, Repair Group 44, Tightening torques for wheel bolts Note: After replacing brake pads, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position. Check brake fluid level after replacing brake pad. Brake caliper, removing and installing Special tools, testers and auxiliary items required

40 Стр. 40 из 45 Torque wrench V.A.G 1332 Socket XZN 16 T10198 Brake pedal actuator V.A.G 1869/2 Removing Work procedure applies only for replacing or when performing subsequent service work on brake caliper. - Remove wheels.

41 Стр. 41 из 45 - Connect bleeder hose of bleeder bottle to bleeder valve of brake caliper and then open bleeder valve. - Insert brake pedal depressor V.A.G 1869/2. - Close bleeder valve and remove bleeder bottle. - Remove brake line from brake caliper. - Remove brake pads 46-2, Brake pads, removing and installing. - Pull wheel speed sensor wire out of bracket at brake caliper. - Remove brake caliper from wheel bearing housing. Installing - Bolt brake caliper onto wheel bearing housing. - Install brake pads 46-2, Brake pads, removing and installing. - Install brake line on brake caliper. - Press wheel speed sensor wire into bracket at brake caliper. - Remove brake pedal loading device V.A.G 1869/2. - Bleed brake system 47-4, Bleeding braking system. - Install wheels. Tightening torque specification for wheel bolts Repair Manual, Suspension, Wheels, Steering, Repair Group 44, Tightening torques for wheel bolts Note: Before moving vehicle, depress brake pedal several times firmly to properly seat brake pads in their normal operating position. Check brake fluid level. Tightening torques: Socket head bolt to wheel bearing housing 150 Nm plus an additional 90 (1/4 turn)

42 Стр. 42 из 45 Use new bolts! Brake line to brake caliper 14 Nm Brake shoes, removing and installing Special tools, testers and auxiliary items required Bracket with spindle and hook 3438 Socket XZN 16 T10198 Removing - Remove wheels. - Remove brake pads - Pull wheel speed sensor wire out of bracket at brake caliper. - Remove mounting bolts of brake caliper. - Remove brake caliper housing and secure with wire so that the weight of the brake caliper does not burden or damage the brake hose.

43 Стр. 43 из 45 - Remove locking bolt - arrow - for adjustment nut of parking brake. Set back parking brake: - Turn adjustment nut - A - against resistance from pullspring - B -. - Remove brake disc/brake drum. - Unhook pull-springs. - Remove spring dowel sleeves with compression springs and remove brake shoes. Installing Installation is in reverse order of removal. - Adjust parking brake 46-2, Parking brake, adjusting. Parking brake, adjusting Note: Adjustment must be made at both adjustment mechanisms of the rear axle. The foot operated parking brake lever and the transfer module on the center console must not be adjusted.

44 Стр. 44 из 45 Make sure the parking brake cable is routed and guided correctly. If the brake shoes have been replaced then the free travel must be set to the 6th tooth, and the brake shoes run-in must be done by a single braking maneuver from approx. 50 km/h. - Parking brake pedal lever in rest position. - Remove rear wheels. Note: The brake discs must move freely. Press a brake shoe back slightly or pull the rear brake cable to and fro, if necessary. - Remove plug - arrow - for parking brake adjustment nut. Adjusting brake shoes on both wheels: - Insert a screwdriver through the hole in the brake disc

45 Стр. 45 из 45 and turn adjustment nut - A - back against the resistance of the spring - B - until the brake disc can no longer turn. - Loosen adjustment nut around the 6th tooth. The brake disc must then be able to turn freely. - Check free travel at foot operated parking brake lever. - Install wheels. Checking foot operated brake lever free travel: Depress foot operated brake lever until it is set on 2nd or 3rd tooth. Wheels must turn without the brake shoes touching/scraping. Depress foot operated brake lever until it is set on 5th to 7th tooth. Wheels must lock. If the wheels turn then the parking brake must be adjusted.

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